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Program Manager Engineer

Farmington, Michigan, United States
January 21, 2018

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Muhammad K. Shahab, MS

West Bloomfield, MI 248-***-****

Self-assured Mechanical & Electrical Engineering Program Manager for interior Systems with 20 years of progressive, dynamic automotive industry experience on a global scale. Tenacious and driven, challenged to excel both independently and as a team member. Adept at launching projects and managing efforts from start to end. Skilled in providing project deliverables on time, within budget and in a manner that surpasses customer expectations. Thrive under pressure in fast-paced working environments. In pursuance of an Engineering Program Manager role that will offer career growth opportunities and a chance to utilize leadership savvy. Willing to engage in career travel for the right opportunity.

Areas of Expertise

Supply Development Customer Relationship Management Continuous Improvement Business Development CQI

Production Part Approval Process (PPAP) Deliverables Lean Manufacturing Quality Assurance Root Cause Analysis

Local & Global Design Business Leader Customer Needs Assessment Goal Definition Project Reviews Risk Mitigation

Creative Problem Solving Meeting Planning Logistics Profit Growth Cross-Functional Team Leader Organization

Attention to Detail Time Management Interpersonal Communication (English, Korean, Urdu) Engineering Principles

Advanced Product Quality Planning (APQP) GD&T, DVP&R, VAVE Microsoft Office Project Management Software

Highlights & Programming Achievements

Proved vital in introducing an innovative Waste Management technique and CIS for the National Bus Center, managing all chemicals, safety data sheets and staff training, as well as protecting EPA safety procedures

Led Henniges to earn an award for Best Program Support from supplier; also saved $5.8M in warranty cost through Continuous Improvement System (CIS), including design optimization, value analysis and engineering, Lean Manufacturing and waste management

Called on claims and change management, along with continuous improvement VAVE activities in overseeing series production and price negotiation efforts for Key Safety Systems

Introduced a Risk Management Program for Lear Corporation that included parts delivery to customer during builds, plant waste control, Lean processes, a decrease in assembly plant turnover, corrective action and training for floor employees; sought to empower staff via appreciation award and other methods

Introduced a Waste Management Program within the Lear plant in Sweden by implementing training and establishing sub-assembly stations; controlled staff turnover, reduced variation and improved both product quality and consistency

Spearheaded seamless Hyundai Expat Assignments NF and CM for a seating program in Korea and the U.S., completed on time and with improved quality; garnered savings of $2M for Lear Corporation as a result

Secured $1.5M in GM cost savings through CIS for the EV1 Plant in Lansing; improved door system quality through GD&T method that controlled variable monitoring

Launched the EN and FN Ford programs for the Grand Marquis vehicle; managed everything from concept to manufacturing

Chosen by Ford’s Purchasing Department to choose global suppliers for the Engineering Department

Served as Johnson Control’s VAVE Leader and Product Manager during tenure in role; became leader of design optimization, the reason Ford provided an offer of hire while still at Johnson Control

Professional Experience

Program Manager National Bus Center Terra Haute, IN 2014 – 2017

Oversaw hazardous chemical functions for the Body Shop and supervised daily Parts Departments processes. Managed the Safety Data Sheet used to log all chemicals. Introduced various Lean Manufacturing practices and Advanced Process Quality Planning (APQP) into Bus Center operations, including Body Shop, Parts Department, Services Department and Uplift Department to add customized parts. Worked with customer daily to ensure all of their respective needs were met. Executed a comprehensive Continuous Improvement plan. Proposed to customers how product reliability can be improved by monitoring the service procedure and using the best quality replacement parts. Upgrade interior system as per customer need

Achieved Q1 status for the first time in the Center; previously, the Center quality standard was poor and unorganized, with no proper training for chemical usage, etc.

Earned safety control recognition and certification through the EPA

Successfully passed Safety inspection for all the chemicals in the Center

Interior System uplift as customer demand and satisfaction.

Sr. Engineering Program Manager Henniges Automotive Auburn Hills, MI 2013 – 2014

Launched a door weather strip system for GM Equinox from concept to manufacture using engineering best practices. Followed all the engineering disciplines and met all customer deliverable on time without any defect in assemblies.

Sr. Engineering Program Manager Continued

Led verification testing and validation in cross-functional team settings. Improved product profit margins using optimization methods such as DOE/DV testing and prototype build fit and finish. Drove continuous improvement for the product launch and related carry-over items. Worked with customers at all product development phases to align optimally with their expectations.

Introduced a flawless body seal for GM products at the Delta Plant and supported all builds in doing so

Improved the warranty of the product three, six and 12 months in service (MIS) using Lean manufacturing, waste management and quality control best practices

Engineering Program Manager for Interior Safety System Key Safety System Sterling Heights, MI 2010 – 2013

Oversaw operations for the Ford Fusion Seat Belt Program including quotes, purchasing, product engineering, quality assurance, manufacturing, launch management and budgeting/finance. Also managed documentation, timelines, technical performance and corrective action initiatives as needed. Leveraged interpersonal acumen in developing and sustaining lasting customer relationships, as well as in leading valuable, engaging business plan meetings. Developed and set forth 3-7 year plans for customer, detailing how supplier would monitor the quality of the product and implement continuous improvement by using the latest technology. Led all facets of the change management process (tell more re: your role) Reviewed internal change management process with customer and ensured suppliers were committed to supporting customers’ needs and exceeding expectations. Liaised effectively with customers to surpass their expectations. Executed Risk Management processes for the Program which included product delivery for all the builds. Also determined how suppliers would maintain product quality and type of support during build and after at the three or six MIS marks. Led management reviews, manage corrective action processes, internal audits and documentation of record controls.

Used VAuct to generate sizable cost savings, as well as optimization, VAVE and waste management

Adhered to critical build times using program timing and milestone build event to launch in Hermosillo, Mexico

APQP Deployment Lead Engineer Caterpillar Peoria, IL 2007 – 2010

Implemented APQP during the design of a Wheel Loader & Motor Grader CAB seating system. Crafted DFMEA and DVP&R for the seating system and sub-system level. Designed and developed DFMEA (Design Failure Mode Affect Analysis, Design Verification Plan and Report (DVP&R) living documents; updated as per need for the program.

Ensured supplier quality at all phases of the APQP process by developing all engineering testing and reporting

Used VAVE to lessen costs and boost profit by benchmarking similar product and implementing best concepts

Implemented CIS for design and plant; saved $3.5M for the company using CIS waste management, VAVE and optimization of the product

Engineering Program Manager for Interior System Lear Corp. Southfield, MI 1999 – 2006

Directed a full-scale engineering effort for customers SAAB 93, Volvo v70 and XC90. Contributed actively to each from concept to manufacturing, including management of all change processes. Headed customer support meetings each week to deliver outcome feedback to Managers and Engineers regarding design direction. Interfaced effectively with the customer to ensure alignment with expectations and specifications. Oversaw the Series Production Phase including claims management, change control and VAVE process improvements. Made continual price adjustments as needed upon successful completion of negotiation efforts. Conducted management reviews, manage corrective action systems, ran internal audits and document record controls. Documented actions, adjusted timelines, managed technical performance, ensured budget adherence and controlled production to ensure quality deliverables. Coached, mentored and supervised a focused team of 25 Engineers including Components Engineers. Developed a testing plan, as well as a Fit and Finish Review to be completed with customers, a Ford procedure that approved plastic covers’ grain. Secured Product Approval Process (PAR) approval from internal management. Prepared the documents and convinced management to offer approval. Created Program Plan, Roadmap Investment and Feasibility Commitments; devised the plan for product development to align with customer expectations.

Secured $4.5M in savings using the CIS program, thus improving product quality and saving money by optimizing the product; also implemented Lean Manufacturing and waste control measures

Saved $2.5M on its interior system processes via the VAVE program including the I/P and seating system as part of the VOLVO & SAAB Expat Assignment

Efficaciously launched the Volvo/Saab V70, XC90 and SAAB 93 projects on time; stayed within budget for all three in a flawless manner that adhered to customer specifications

Senior Lead Engineer, EV1 Door System Engineer General Motors Corporation Troy, MI 1996 – 1999

Vastly improved the quality of the SMC door through dimensional control analysis. Earned appreciation from GM in the form of the “Fabulous Quality Improvement Team Leader” honor. Also named CIS Champion of GM Lansing plant for EV1 vehicle.

Senior Product Engineer Ford Motor Company Dearborn, MI 1989 – 1995

Oversaw the entire switches program; selected by Ford Purchasing to choose global suppliers from the Engineering Department. Saved $250M for complete interior system in not recalling the switches. Also improved the quality of the product by 40% using various optimization efforts. Served as the VAVE/CIS organizer and leader for the group.

Product Engineer Johnson Control, Inc. Livonia, MI 1986 – 1989

Managed development of a complete seat product including components release, sub-assembly and assemblies. Developed engineering discipline including DFMEA, PFMEA, FA AND DFA. Coordinated seamless testing process in conjunction with Testing Engineers. Offered customer support for the PN96 program. Developed engineering specifications for the Power Seat Track in a manner that exceeded customer expectations. Aided in organizing the Product Engineer engineering discipline.

Education & Credentials

Master of Science, Engineering Management, University of Detroit Mercy, Detroit, MI (3.8 GPA)

Master of Science, Electrical Computer Control System, Wayne State University, Detroit, MI

Master of Science, Mechanical Engineering, Wayne State University, Detroit, MI

Bachelor of Science, Mechanical Engineering, NED University

Training Completion, Six Sigma Leadership, Lear Corporation

Certified, Lean Six Sigma Black Belt, Lear Corporation

Certified, Professional Engineer (PE)

Professional Affiliations

Society of Automotive Engineers (SAE)

American Society of Mechanical Engineers (ASME)

Detroit Society of Engineers-Professional Engineer (DSE)

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