Engineer Manager
Resume:
Print Save as PDFByron L. Brock
South Lyon, MI 48178
***********@*****.***
OBJECTIVE
Engineering or Program Manager leading product design/launch and cost reduction teams in an automotive or manufacturing environment. In depth understanding of engineering tools and manufacturing processes used to assemble automotive seat systems, interiors systems and ABS braking systems and their sub-components. Excellent verbal and written communication skills using MS Office, Power Point, Project, etc.
EMPLOYMENT HISTORY
TRW Automotive / Volt Technical Resource, Livonia, MI
03/2008 - 09/2008Program Manager
PROGRAM MANAGER PRODUCT PLANNING (CONTRACT SSIGNMENT) Brought in to lead Hydraulic Power Steering GROW Goal Reality Options Will do Project Core Team and report progress to company executives. Work across departments to improve business unit financial performance globally- overall project savings estimated at $48 million. Identified $2.5 million savings on purchased parts eliminated multiple prices for the same part. Mapped business growth/contraction using Excel pivot tables with market database. Identified transitions to new technology or competitors and retrofit opportunities by OEM, region, etc. Identified global best practices to produce gear assemblies and components and facilitated transfer of assets between plants. $7 million cost avoidance achieved by transferring assets to LCC. Rewrote GROW procedure manual used Statement of Work approach. Lead supplier design/cost reviews with engineering and purchasing. Applied new detail quote data to DFM software which drove lower cost designs in support of regional price targets
GLOBAL AUTOMOTIVE SYSTEMS / G-Tech, Royal Oak, MI
11/2007 - 02/2008PROGRAM MANAGER
Brought in three weeks before SOP to identify and resolve Launch and Personnel issues at Lexington Metal Systems; Improve Communication and lead team through successful HVPT runs for Toyota 200L and 150L programs. Interface with Sr. Management, Plant Staff and Customer (Trim Masters, Inc.) representatives. Implemented a systematic approach to identify, track and resolve process, personnel and quality issues. Used Open Issues Lists, Corporate APQP process and TMI SQUAM manual to drive issues to closure. Demonstrated Problem Solving techniques to Production Management and floor supervisors. Recommended changes in product design, production machinery and operators to improve quality and efficiency. Worked with equipment builders and internal tool room staff to revise fixtures and robot sequences to improve welding and riveting processes. Implemented visual management tools for production and quality. Created production boards to track hourly production & issues and eliminate short & expedited shipments to customer. Used Pareto charts to compare defects found at customer and two different 3rd party containment sites. Charts were used to highlight quailty issues
Ford Motor Company / Kelly Services, Dearborn, MI
08/2007 - 10/2007Design & Release Engineer
Brought in to lead 2010 Taurus second row seat design, release and testing; guide development of complete seat and bolsters, including foam, trim and structures. Interface with Program Managers, Purchasing, Design, suppliers and other activities within FMC. Executed comprehensive design reviews with studio, designers and suppliers; review changes between Milestones FC4 and FC5 STO from studio with designers and engineers from other functions. Release JIT and Assembly Plant components using WERS and AVBOM Perform studies using TCE viewer and Digital Buck to show interface / interference conditions between seat frame, package tray and seat back latch. Created business case to compare design options for carry-over seat structure vs. package tray support assembly on piece cost and tooling.
Chrysler Corporation / TAC Automotive, Auburn Hills, MI
02/2007 - 06/2007Component Cost Analyst
Brought in to spearhead analysis, negotiation and approval of supplier quotes for Piece Cost, Tooling, Capital Expense and ER&D; initiatives complemented engineering changes on vehicles including Jeep Compass, Jeep Patriot, Dodge Caliber, Chrysler PT Cruiser and Jeep Wrangler. Executed comprehensive reviews of piece cost with roll-up for IBT, SGA and profit as well as detailed breakdown of ER&D expenditures; generated DCX comparison pricing on piece price for trim, plastics and metals; reviewed costs relative to new and revised tooling and capital; developed capital amortization schedule (to apply capital and ER&D to piece price). Regularly negotiated with suppliers for piece cost, tooling, capital and ER&D, including test costs. Successfully negotiated over $10 million in savings including: $1.5 million for removal of ODS from front seats and change of rear seat release handle to pull strap; $200,000 for addition of SAB to PM/MK seats; 82.16 per vehicle for seat set on right hand drive postal vehicle; $2.45 million for trim changes on Jeep Wrangler Program. Assigned to generate approved DV/PVtest cost matrix which saved $1500 per I/E test
Johnson Controls, Inc., Plymouth, MI
05/1992 - 10/2006Engineering Manager
Managed 2008 & 2009 Expedition / Navigator Program to meet FMVSS 202a, Core SCT Module, 2nd row ez-entry heated seats and 3rd row excursion reduction. Negotiated #3.5 million program budget with Ford Engineering. Utilized Program Launch systems to generate designs. Led Cost Reduction Team of five engineers to annualized savings of 45.8 million. Created new process to systematically evaluate feasibility based on engineering, program timing, implementation cost and customer milestones. Quoted ED&T to Ford Motor Co. for each proposal. Managed F150 Truck Seat Engineering team through nine product launches. Product Engineer for Power Seat Track mechanisms on Ford and GM vehicles.
Bendix Automotive Brake Systems, South Bend, IN
07/1987 - 09/1991Project Engineer
Designed Anti-skid and Traction control systems for medium heavy trucks. On-site Plant support engineer for all Chrysler ABS systems at St. Joseph MI manufacturing plant. Evaluated manufacturing deviations for master cylinders, control modules and hydraulic pumps through tear down analysis and tolerance stack-ups. Design and release engineer for Jeep Cherokee XJ ABS system providing launch support and on going product development with manufacturing.
EDUCATION
BSME
Major: Mechanical Engineering / Design
Michigan Technological University, MI
CERTIFICATES AND LICENSES
EIT, Dept of Commerce, MI
Certified Detailer, Marysville High School, MI
SKILLS AND ABILITIES
Comprehensive understanding of product design effects on manufacturing process and cost. Areas of Expertise - Business case preperation and evaluation, Cost Reduction, Product Design, Program Management, Team Management, MS Office software (including MS Project), GD&T, DFMEA, Quality Control, 8D problem solving, SPC, Statistics, DOE and Linear Regression, Progressive and transfer dies, casting and machining processes. Excellent understanding of design and drafting procedures.
NOTES / OTHER INFORMATION
Please email me to request a copy of my resume in MSWord format. Thank you ***********@*****.***
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