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Engineer Manufacturing

South Lyon, Michigan, United States
August 09, 2018

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248-***-**** 25876 McCrory Ln., South Lyon, MI 48178


Summary: Highly effective and results-driven professional with 20+ years of experience in automotive manufacturing engineering and track record of success devising strategies to increase efficiency and decrease operating costs. Six Sigma Black Belt with expertise in lean manufacturing principles, failure mode and effects analysis (FMEA), advanced product quality planning (APQP), and production part approval process (PPAP).

Respected leader with excellent problem-solving and budget/resource allocation skills, impeccable attention to detail, and exceptional process development abilities. Valued team member with dedication to continuous improvement and commitment to streamlining manufacturing procedures and enhancing flow of people, materials, and information.

Strengths Include:

Statistical Process Control (SPC)

Project Management

Quality Assurance

Estimating and Procurement

Process Design

Just-in-Time Production (JIT)

Continuous Improvement

Equipment and Plant Layouts

Automation & Robotics


Increased production on “C” sedan automated catalytic converter cell as Plant Engineer for Eberspaecher North America, increasing efficiency from 15% to 85% over 10-month period.

As Senior Resident Quality Engineer for Robert Bosch, LLC, launched 6-speed FWD and RWD transmission control modules, monitoring products for 3 years and reducing defective rates from 2K PPM to 50 PPM by guiding 8-D teams in identifying root causes and devising permanent corrective actions.

Delivered numerous significant contributions as Senior Manufacturing Engineer for Ford Motor Co., earning recognition as “Outstanding Performer” 7 times by 4 different supervisors during 10-year tenure (rating given to top 5% of engineering staff annually):

-Spearheaded project that generated $400K in annual savings on most highly automated throttle body line in the department (4.6L engine) with zero interruption to production.

-Served as lead engineer on most ambitious project in group’s history, developing automated line with 26 online stations building throttle bodies for 5 separate engine families with cycle time of 9 seconds per part.

-Chosen out of 18 engineers to work on Ford’s first drive by wire electronic throttle body and solved worst ergonomic issue for operators (manual winding of torsion spring) that resulted in 3 US patents.



Resident Quality Engineer

Perform failure analysis on automotive ambient lighting products. Manage customer quality concerns. Conduct regular customer visits. Analyze historical warranty and champion improvement activities. Champion 8D problem resolution, root cause, corrective action implementation and follow up as required. Manage on-site containment activities.

JOHNSON CONTROLS, INC. Plymouth, MI (2014–2016)

Advanced Manufacturing Engineer

Recruited by former supervisor at Ford Motor Co. to lead complex, high-volume project creating seat track assemblies for multiple future car models. Administer multimillion-dollar budget, compile production equipment specifications, issue requests for quotations (RFQs), and collaborate with global counterparts to ensure process standardization.

Established capital and tooling budgets for stamping, Gas Metal Arc Welding (GMAW), laser welding, and assembly equipment.


Plant Engineer/Advanced Manufacturing Engineer

Enlisted by company President to resolve issues with “C” sedan automated catalytic converter cell that was running at 15% efficiency, forcing 24/7 operations to meet production demands. Transitioned into Advanced Manufacturing Engineer role and presided over selection of vendors for 2 new cells including writing specifications and RFQs.

Cut payroll expenses by eliminating 2 positions after reworking operator ergonomics and material flow.

FORD MOTOR CO. Dearborn, MI & Hermosillo, Mexico (2011–2012)

Vehicle Operations Manufacturing Engineer

Returned to Ford Motor Co. to assist with and direct installation and startup of body shop robotic weld cells for underbody structure of 2013 Ford Fusion model. Traveled to plant in Hermosillo, Mexico to manage vendors on site and help with debugging/troubleshooting tasks.

ROBERT BOSCH, LLC Farmington Hills, MI (2005–2011)

Senior Resident Quality Engineer

Originally hired by wholly owned subsidiary of German multinational engineering and electronics company to represent Charleston, SC plant producing transmission control modules for Ford Motor Co., serving as primary point of contact for failure analysis and technical/quality issues. Subsequently transferred to calibration role, performing in-vehicle testing and validation of Engine Control Unit (ECU) software.

Quickly gained proficiency in ETAS INCA software used for ECU testing/validation, inducing up to 500 failure modes and documenting results to uncover bugs and expedite software release.

VISTEON CORP. Plymouth, MI (2001–2005)

Senior Manufacturing Engineer

Joined automotive parts supply company that was spun off from Ford Motor Co. in 2000. Managed multiple equipment builders, schedules, quality activities, and budgets. Guided associates, team and group leaders, and personnel from various trades, delivering comprehensive training and participating in hiring process. Created equipment bid specifications and all related process documentation. Designed lean assembly and testing procedures to optimize flow of materials, information, and employees.

Conceptualized, developed, and launched new front end module assembly line providing parts to Ford’s Chicago plant via JIT delivery/in-line vehicle sequencing (ILVS), working closely with logistics department to implement “A Plan for Every Part” strategy that enhanced inventory levels at line side as well as incoming parts marketplace.

Successfully completed training and exam to earn Six Sigma Black Belt.

FORD MOTOR CO. Ypsilanti, MI (1991-2001)

Senior Manufacturing Engineer

Joined Ford Motor Company to boost Assembly and Test groups’ Controls Engineering capabilities. Immediately began leading skilled trades completing equipment installation/rework, pneumatic and hydraulic piping, wiring, logic debug, and releasing to equipment to production. Additional duties: daily production support of existing throttle body assembly and test lines. Improved process Overall Equipment Effectiveness (OEE) by identifying equipment availability, quality rates, and equipment performance. Developed and implemented corrective action plans. Quickly advanced to Forward model role responsible for concepting multiple new product assembly and test production lines. Specified, evaluated vendors, and acted as lead engineer during equipment design, build, startup, debug, and runoff at vendors. Lead installation, startup, capability studies, training, and release to production. Compiled and executed actions plans and achieved 85% or greater OEE before moving on to new projects. Created PFMEA’s, Control Plans, Process Sheets, and other process documentation. Completed Gauge R&R and capability studies. Analyzed data using Minitab. Identified sub-standard gauges (GR&R > 10%) and assembly and test processes (CPK < 2.0). Implemented corrective actions to bring gauges and stations into compliance.

Successfully implemented assembly and test production systems ranging from manual lean cells (50K-150K units annually/25 second TAKT) to automated systems (1M+ units annually/9 second TAKT).

Departmental Controls resource for Allen Bradley PLC-5, SLC-100/500 and Panel View’s, pressure decay, mass flow, and Helium mass spectrometry leak test systems, DC and pneumatic fastening systems, Nordson coating systems, servo and air/oil Bearing presses, Riveting, and Adept robots.

Identified corrected quality, performance, ergonomic, and safety issues on assigned equipment and others loaned to other departments to consult and assist in problem solving as needed.


Controls Engineer

Lead automated material handling system Controls Engineer for customers including General Motors, Inland Steel, and Chrysler. Systems included passenger car sheet metal assembly weld presses, overhead Power and Free and Dragline style conveyor systems, hydraulic transfer cars, and Automatic Storage and Retrieval Systems (ASRS). Designed and detailed AutoCAD control panel layouts, wiring, pneumatic, and hydraulic piping schematics. Selected controls devices based on customer requirements. Wrote Allen Bradley, Mitsubishi, and Reliance Electric PLC ladder logic, Basic, and Pascal programs.


BS – Electrical Engineering Oakland University, Rochester, MI

Six Sigma Black Belt Certification – Visteon Corp.

Additional training through Ford Motor Co./Visteon Corp.:

Lean Manufacturing, Error Proofing, Value Stream Mapping (VSM), Statistical Process Control (SPC), Ergonomics, Line Balancing, 8D Problem Solving, Constraint Theory, Project Management, Production Part Approval Process (PPAP), Advanced Product Quality Planning (APQP), A Plan for Every Part, Measurement Systems Analysis (MSA), Geometric Dimensioning and Tolerancing (GD&T), Design for Assembly and Manufacturing (DFAM), CPARS, PCPAS

Computer Skills: Team center PLM, SAP, Minitab, ETAS INCA, CANalyzer, AutoCAD, MS Project & Office Suite (PowerPoint, Excel, Word, Outlook)


6,070,852 – Electronic Throttle Control System. 6,647,960 – Torsion Spring Assembly for Electronic Throttle

6,672,280 – Torsion Spring Assembly for Electronic Throttle

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