Engineer Engineering

ANN MARIE O’CONNELL, P.E.

**** ***** ***** *********: 734-***-****

Plymouth, Michigan 48170 Cell: 734-***-****

Email: ****@*******.***

CAREER SUMMARY

I am a certified Six Sigma Black Belt and licensed Professional Engineer with extensive experience in lean manufacturing, value management, manufacturing automation, and concurrent product and process development. I have expert skills in multiple product and process improvement techniques, and a proven ability to improve product and process quality, increase yield, and decrease costs. I possess excellent analysis, speaking, writing, listening, training development and delivery, and team facilitation skills.

CAREER HISTORY

Adient (formerly Johnson Controls), Plymouth, MI 2012- Sept 2017

Engineering Manager, Continuous Improvement

Improve productivity and effectiveness of the Product Development and Validation Processes by:

Identification, pilot, and implementation of new technologies, procedures or business processes to reduce time and cost, improving profitability and product quality.

Application and coaching engineering staff in application of VA/VE, Six Sigma and Design for X techniques.

- Recent targeted workshops produced $100-300k of implementable savings ideas per session.

Creating and calculating business process improvement metrics. Coaching engineering managers and directors in using these metrics to measure and sustain operational improvements.

- Ongoing reporting of tooling change cost metric and tool design dependencies saved over $1M / year from start of project.

Using Value Stream Mapping and 5 Why tools to define training requirements for organization-wide PLM implementation.

Developing role-based and task-based training modules for organizational PLM training, including screen capture, video editing and narration script devel.

MCU, LLC. Plymouth, Michigan 1985-present

Full time 2002-03, 2006-2012

Principal Consultant

Identified and solved efficiency, effectiveness, automation, and cost problems for individuals or organizations.

Organizing equipment, space, records and procedures for small businesses and households

Edited product definition and market-segmentation documents for complex AMI systems

Consulting for multiple organizations on moving from proof-of-concept pilots to mass production

Developement of hands-on, multi-sensory workshops to teach science and engineering principles

Provide consultation on assistive technology and statistical analysis of student sub-group performance to local school districts.

CORSA INSTRUMENTS, Ann Arbor, Michigan 2003-2006

Manager, Marketing, Sales and Customer Satisfaction

Developed and implemented lean production and testing procedures for low volume, semi-custom electronics design and manufacturing firm. Improved productivity by 35%.

Conducted focus groups and served as “Voice of the Customer” for Corsa's product development process.

Represented Corsa in meetings and large events for multiple motorsports / vehicle competition communities and to OEMs requiring in-vehicle data acquisition.

Developed customized sensor configurations and calibrations to meet specialized customer needs.

Applied Design for X methodologies to both product and production processes.

Analyzed, designed, implemented and documented new procedures for product definition, product development, sales, shipping, service, and marketing communications.

FORD MOTOR COMPANY, Livonia, Michigan 1988-2002

Powertrain Operations. Manufacturing Engineering

Six Sigma Black Belt 1999-2002

Solved problems using statistical and other tools to improve customer satisfaction and reduce costs.

- Projects included: Multiple targeted DOEs to optimize processes, resulting in doubled part life without additional capital investment; using production process traceability system to oprtimize cutting tool change scheduling; air leak identifiation and repair to reduce compressed air and overall energy useage.

Facilitated cross-functional teams which identified Critical to Quality characteristics of products and processes, and reduced their variation, increasing customer satisfaction and reducing direct costs by an estimated $14/unit and capital investement by over $10M per program analysed..

Served as “Master Trainer” for Green Belt Technical Training; Delivered 6 week-long sessions / year to engineers and production supervisors/managers, each with a different inexperienced co-trainer.

Designed and implemented a web-accessible database of process capability information on CTQ characteristics for Ford PTO which enabled DFSS savings of $10-35 million per powertrain program.

Optimized a chemical / mechanical finishing process to improve product life by 100% while avoiding capital investment of $1.8 million for additional finishing equipment.

Planned and conducted Lunch and Learn seminars for the Powertrain Black Belt and Technical Specialist Community.

Technical Specialist: Design for Manufacture and Value Management 1992-1999

Served as Ford PTO internal consultant on Design for X and Value Engineering / Value Analysis techniques.

Planned, organized and conducted workshops to reduce cost and improve quality of all new, major change and existing Automatic Transmission (ATEO) products or processes.

Lead over 100 Value Analysis or Kaizen workshop teams as part of the Ford VA Blitz which identified and prioritized feasibility of product or process changes worth over $5 million in material cost savings.

Developed and conducted a single workshop using both Design for Manufacturing and Value Engineering /. Analysis tools, reducing engineering costs by $500,000 and development time by two weeks per program.

Served two terms as Chair of Ford's Technical Specialist Administrative Committee. Planned and executed multiple internal “trade shows” and an annual conference to facilitate technology deployment for the Technical Specialist Community.

Developed and reviewed test questions for the Manufacturing Engineering Professional Engineer exams in cooperation with the Society for Manufacturing Engineers and ETS.

Served on technical committee to evaluate parametric design tools, including Pro-E, Catia, and Unigraphics, for Ford Powertrain Operations. Investigated addition of Axiomatic Design tools to FPDS.

Drafted three chapters and edited final document of SAE Design for Manufacturability Best Practice Document, resulting in simpler, less expensive adoption of DFAM by auto suppliers.

Advanced Manufacturing Process Engineer 1988-1992

Responsible for development and implementation of new improved manufacturing processes to support powertrain production operations.

Introduced magnetic flux scanning technology to identify “bonus” parts in automatic transmissions without use of X rays, reducing repair and warranty costs by $500,000 the first year.

Designed flexible, ergonomic work stations for Dynamometer Techs, which incorporated assembly line fixtures and electric nut runners to support PTO-wide “Make Like Production” initiative.

Introduced pneumatic functional testing for automatic transmission sub-assemlies, reducing hydraulic oil usage, oil exposure of employees, and improving plant housekeeping dramatically while improving productivity and quality.

TEXAS INSTRUMENTS, INC., Farmington Hills, Michigan 1986-1988

Factory Systems Automation Group of TI provided automation and systems integration services for aerospace, appliance and automotive manufactures.

Systems Engineer 1986-1988

Responsible for needs analysis, design and implementation of manufacturing automation and expert systems.

Developed a diagnostic expert system for an automotive OEM, which reduced their warranty costs on covered systems by 35%.

Developed next generation of diesel engine and semi-truck powertrain 3rd party diadnostic system using CAM connections, advanced signal analysis of operating signatures and AI diagnostics.

Developed flexible-format marketing brochure addressing the entire range of products and services available, which led to a 200% increase in Requests for Proposals / Quotation to the FSA group vs prior year.

GENERAL MOTORS CORPORATION, Ypsilanti, Michigan 1975-1985

HydraMatic Division. Now part of GM Powertrain Division.

Manufacturing Planner 1985

Responsible for assessing manufacturing capacity and capability of five plants producing seven major product lines.

Lead developer of GM’s first manufacturing capacity planning model to support scenario planning and product plans.

Skilled Trades Supervisor 1984

Scheduled and prioritized work assignments for skilled trades workers in three classifications during launch of an automatic transmission program in a former axle plant.

Provided support to axle manufacturing engineers as they learned automatic transmission processes and equipment.

Industrial Engineer 1981-1983

Tracked direct and indirect labor performance to budget.

Analyzed cost reduction impact of projects.

Supported implementation of Office Automation by measuring white-collar productivity, identifying over $2M/ year in productivity enhancement opportunities.

Product Development Engineer 1980-1981

Developed multiple production calibrations, and scheduled prototype parts, technicians, dynamometers cells, and vehicles for a new FWD transmission program.

Co-op Engineering Student 1975-1980

Assignments included product design, manufacturing engineering, personnel, tool design, production supervision, instrumentation laboratory, skilled-trades supervision, industrial engineering, and IT operations.

EDUCATION

MBA, Information Systems & Operations Management, The University of Michigan, Ann Arbor, MI 1985

BSME, General Motors Institute (now Kettering University) Flint, Michigan 1980

Mechanical Engineering - Manufacturing Process Engineering specialty

TRAINING & CERTIFICATIONS

Design for Six Sigma – powertrain course developer

Ford Certified Six Sigma Black Belt – Technical

Factory Physics – UM CCEU

Licensed Professional Engineer – MI # 620XXX386

Design & Process Failure Mode and Effects Analysis

Systems Engineering – UM CCEU

DFM / DFA – BDI Certified Trainer/Facilitator

FPS Lean Manufacturing / FPS Implementer

Design for Environmental Sustainability – UM CCEU

Curriculum Design and Development

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