Engineer Engineering

Thomas Koller

**** ********* ***, ***** ********, South Carolina 29466 Phone: 716-***-**** e-mail: ********@*****.***

Summary

Senior Lean Manufacturing and Industrial Engineering Professional

Industry Concentrations

Automotive Powertrains, Aerospace Propulsion, Structures and System Assembly and Integration, Composite Fabrication

Experience

•Leader and management of cross functional Teams partnering with Operations and Customers to deliver World Class powertrains, propulsion and aerospace products utilizing advanced automated and semi-automated assembly and material handling systems, robotics, multi-function end effectors and machining centers within a modern Lean design and functional framework. Factory/Site Acceptance Testing and systems sustainment. Comprehensive experience with International projects, processes and customers. Industry Standard knowledge of automated assembly, machining and fabrication of engines, transmissions and components including clean room environments in multiple global locations (Japan, Mexico, Germany, Italy, Korea).

•Collaboration with internal and external Design Engineering teams and firms providing RFPs/RFQs, Design and Supplier down-selects/final selections, Preliminary Design Reviews, simultaneous engineering, Critical Design Reviews, improvements and Final Design Reviews/approval.

•New Business Development focusing on segment and regional demands/requirements versus product performance. Collaborative designed in quality to satisfy voice of customer and price point at maximum margins. Senior level business acumen and market knowledge of Automotive, Aerospace and related Tier II, III industries.

•Expert level in the application of Industrial and Manufacturing Engineering best practices. Broad spectrum experience and Project

Management in areas of new technology introduction and development for production usage, planning and implementation of new facilities and product launches, PPAP, rate readiness and ramp-up, model year and process changes including critical path management, constraint based scheduling, capacity analysis, estimating, budgets, capital justification, appropriation authoring, layout, AutoCAD, procurement, supply chain and logistics, supplier management, operations, quality management, simultaneous engineering, design, run-off, installation and commissioning.

•P&L advisor/stakeholder utilizing KPIs, commodity management, intelligent metrics, business climate and voice of the customer. Invested in a people, process and parts approach including environmental factors to manage the business.

•Maximization of system efficiencies and capacity using six sigma Lean methods, measurement and metrics development, zero defect targets, continuous improvement, optimal system, logistic and workflow sequencing, kitting, just-in-time methods, waste elimination and team problem solving to produce the highest quality products safely.

•Expert level in Greenfield/Brownfield start-ups performing Rate Readiness Assessment activities with both internal and external customers. Experience directing supplier turnarounds due to quality concerns or issues. Supplier selection and Readiness assessment.

•Lean Operations assessment and practice, facilitation, implementation and sustainment (5S, Value Stream, Kaizen, Six Sigma, PDCA, Gemba).

•Conduct labor and machine studies, cutter and tooling studies, audit development, forecast headcount, flow projection and reduction, constraint and downtime analysis, FTQ improvements, cycle time improvements and work sampling evaluating all PFMEA, safety, quality, ergonomic and environmental considerations.

•Trained Industrial Hygienist, Ergonomist and appointed Safety Focal; multiple locations and industries.

•Promote common systems by maintaining a Global Bill of Process; mentor and advise Global sister facilities. Identify and support Lean initiatives using common processes including Value Stream analysis and Kaizen principals. Author of guiding documentation for common business processes.

•Proficient with the Toyota, General Motors, and Boeing Production Systems including associated software, methods and procedures.

•Regular Leadership, Senior Staff and Director Level interaction and report out. Daily collaboration with Global and Enterprise customers and partners.

•Management of direct engineering/operations/maintenance personnel in union environments including staffing, hiring and training.

Performance History

2013 – 2017 Industrial Engineering Leader, The Boeing Company – 737 MAX Propulsion Division, Ladson, SC

•Lead Industrial Engineer of Greenfield start-up for design, fabrication and production assembly of the 737 MAX Inlet nacelle component.

•Responsible for all aspects of Industrial Engineering Operations including overall Propulsion South Carolina Project Management relative to plant capacity, tooling, scheduling, staffing, automation and resource utilization working with a cross functional start-up team for successful execution.

•Daily collaboration, interaction and innovation with both upstream and downstream Customers while acting as a Tier II internal Supplier to the 737 MAX Program.

•Provide critical Product Design feedback to Design Engineering to enable MFEA, address Production issues, and improve safety and quality.

•Received Innovation Award for process and facility design of 737 MAX Phase II (12/2016) to meet dynamic and flexible Program requirements.

•Utilizing Lean tools and the Boeing Production system conducted VSMs for factory set-up including paper-doll exercises and PDCA follow-up.

•Created and maintained Standardized work for all manual operations.

•Regular Rate Readiness Scorecard report-out to 737 MAX Program and creation of Recovery Plans.

•Ground-up implementation of ERP system. Supplier communication, readiness assessments and management.

•Daily GEMBA walks focusing on bottleneck areas with Operators and Team mates.

•Conduit and implement direction from Senior Management and the Leadership Team to execute the long term strategic vision of business decisions. Primary back-up for Operations Manager.

•IPT member and stakeholder

2011-13 Industrial Engineer IV, The Boeing Company – 787 Dreamliner Program, North Charleston, SC

•Lead Industrial Engineer of Composite Fabrication, Aft Sections 47 and 48. Primary back-up for First Level Manager, responsible for daily departmental cadence, point of contact for manufacturing/support functions and long range business planning.

•Conducted and implemented Lean workshops focusing on 5S practices to streamline shop materials and tooling flows.

•Clean Room experience including layup and Automated Fiber Placement. Post Autoclave Cure fabrication experience including repair and NDI (Non-Destructive Inspection).

•Coach and mentor Associate Engineers in Boeing process and procedures.

•Aft Assembly Subject Matter Expert of Aurora constraint based scheduling software. Lead for plant-wide implementation.

2007-10 Global Engineering Leader - New and Major Programs, General Motors Company LLC, Pontiac, MI; Szentgotthárd, Hungary; Toluca,

Mexico

•Global Lead Process Engineer for GMPT Small Gas Engine Program. Convergence of six (6) product platforms and sixteen (16) Global manufacturing locations to common product, assembly architecture and process.

•GM de Mexico Toluca Lead Process Engineer. Project Manager at Brownfield manufacturing assembly facility to produce the GM Opel Family III engine for import to the United States; Chevrolet Cruze Program.

•Research, design, development and implementation of state of the art piston and rod assembly automation, multi-process assembly cells and automated valve key-up tooling across several powertrain assembly platforms.

•Project Management for repurposed design and introduction of legacy product assembly equipment. Partner with OEMs to retool and redeploy obsolete and underutilized assets.

•Daily collaboration with International partners and Customers including Program Final Assembly sites, Contracted third-party OEMS and GMPT Headquarters.

•Lead team to poka-yoke legacy assembly systems in Mexico to prevent and eliminate defects occurring or being passed to downstream operations.

2000-07 Senior Manufacturing Engineer - New and Major Programs, General Motors Corporation, Tonawanda, NY; Spring Hill, TN; Shanghai, China

•Project Management for implementation and launch of 2009 Ecotec product for domestic market and export; program budget >$300 million.

•Collaborate with Global Customers and Suppliers in planning, engineering and design/build of assembly and machining capital and tooling including ancillary items such as transports, manipulators, and material handling. International experience in both Asia and Europe.

•Create and maintain/conduct standard manufacturing engineering, production and quality documents/procedures including PPAP, TS16949, DFMEA, MFMEA, PFMEA, Control Plans, Error Proofing Plans, Time Study and Cycle Time Databases, Tool Logs and Layered Audits.

•Developed, implemented and demonstrated the GMPT Tonawanda 24 hour Installation Process resulting in zero downtime during complex, system disruptive installations and process changes without impact to Metrics. Final Program cost 15% below approved budget.

•Implementation of first Pilot Area of General Motors Manufacturing System; corporations first Lean Production system at Tonawanda Engine Plant

•Identified and resolved a significant system design trafficking flaw which immediately increased output by twenty units per shift.

•Improved production efficiency 31% and decreased .93 labor hours per unit

Education

Kettering University - Flint, Michigan

M.S. Manufacturing Operations; Certificate Lean and Flexible Production Systems

State University of New York College at Buffalo –Buffalo, New York

B.S. Industrial Technology; Minor Safety Studies

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