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Manager Quality Engineer

Location:
Auburn Hills, Michigan, 48326, United States
Salary:
95000
Posted:
February 16, 2019

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Resume:

Kevin Lohmeier

**** *******

Shelby Township, MI 48316

Home Phone: 248-***-**** Cell Phone: 586-***-****

E-Mail: ac8iiv@r.postjobfree.com

OBJECTIVE:

An Operations or Engineering Management Position where my skills, training and experience can be fully utilized to benefit your company and allow myself to grow further

Education: Mechanical Engineering

University of Detroit Detroit MI

Associate of Science Manufacturing Management

Macomb Community College Warren MI

Member: SME, SAE I have earned a Six Sigma Black Belt

SUMMARY OF QUALIFICATIONS:

I have a broad background in lean manufacturing, tooling, metals machining, systems development and project management from formulation of the specifications through implementation, capital requirements and product launch. With nearly 35 years of manufacturing experience with 15 in automotive, I have focused on implementing total quality, lean/cellular manufacturing and continuous improvement methods for the last 18 years to improve the production process and produce a better product. For 8 years the Toyota Production System has been implemented at two Mark IV and at one Hughes/Tesma plants, the Mark IV plants have UAW unions, my training includes workshops and seminars conducted by Toyota, SME and the SAE. Working with the Product Design Teams for DCX, GM, Isuzu, and Toyota, participated in Value Stream Mapping and the development of and execution of the DVP&R, Design and Process FEMA’s. Working with the customer, engineering and manufacturing teams to optimize the design, improve manufacturability, component functionality from conception through product launch. With a willingness and desire to try new ideas and the ability to blend these with proven methods, I feel my experience and my ability to work successfully with various groups and departments to build a consensus, problem solve, complete a project and to run multiple projects would be of benefit.

My position at JAC Automotive consisted of providing project and manufacturing engineering support for the factory floor and implementing lean manufacturing.

Over five years of experience providing project and manufacturing engineering support to the Chrysler and Saturn Product Lines at Hughes Division (fuel systems) of Tesma/Magna Corp a Tier-1 automotive supplier. I lead a team consisting of 1 manager, 2 supervisors, 8 engineers, 2 toolmakers, the prototype shop, the 6 man maintenance team plant continuous improvement and employee involvement projects that exceeded company goals, this include training and mentoring team leaders and members. Part of a five-person team that implemented TS16949. In a cross-over group worked 6 months to improve forging technique at a sister division and to introduce lean manufacturing methods in the division.

Five years of experience providing project and manufacturing engineering support to the Chrysler and Toyota product lines at Mark IV Automotive (fuel systems) a Tier-1 automotive supplier. Managed 7 engineers, 3 toolmakers and 2 supervisors responsible for organizing continuous improvement teams, completing several projects successfully that improved plant operations, quality and output.

Worked to develop and implement welding and assembly cells at JAC Products, Tesma/Magna and Mark IV Automotive. These cells used vision systems, part present and other poke-yokes to ensure complete parts. Ergonomics for the operators and the flow of components into the cell and assembled components out were optimized. These cells made parts for GM, Ford, Chrysler, Toyota and Honda.

With 20 years of progressive experience with D-M-E a Division of Cincinnati Industries, the largest supplier of process controls, standard and special tooling to the plastic injection industries. At D-M-E I served as a Manufacturing Systems Engineering Manager directing 7 engineers and 2 CNC programmers. Lead the design and implementation of several machining and welding cells at D-M-E. These produced large increases in part quality and production volume.

PROFESSIONAL EXPERIENCE

Contract ended

RGBSI at Magna Seating Highland Park, MI 2/2016 – 4/2018

Quality Engineer

Responsibilities include managing the APQP process for Manufacturing and working with manufacturing insure seating and other interior components meets or exceeds customer requirement

Synova at Chrysler Tech Center Auburn Hills, MI 9/2013- 12/2015

Contract ended

Cost & Capacity Analyst

Cost & Capacity Specialist (Purchasing) Review vendor quotes regarding production volume increases or changes in function. I approve, reject or request changes to the quotes and partake in the APQP process. I work with vendors to match their quotes to Chrysler’s requirements and to judge suitability of the response.

JAC Products Shelby Township, MI 5/2011- 7/2013

Plant partially closed-operation moved

Manufacturing Engineer

Responsibilities include managing the APQP process for Manufacturing and working. JAC manufactures roof racks and cargo handling tie downs.

As part of cross-functional team Six Sigma tools such as DOE & analysis of variation plus other tools such as Design for Manufacturing/Assembly, Lean Manufacturing, VA/VE, Kaizen events, process control methods are used to improve processes, reduce costs and improve quality.

Worked with all plants at JAC Products to direct the implementation of the Toyota Production System at these plants. This included standardized and balanced workload in the cells reducing/eliminating WIP, scrap and excess material movement. Continuous improvement and PM programs were implemented.

Aspect Recruiting Grand Blanc, MI 10/2009-5/2011

Quality Engineer

Contract ended

Assigned to TI Automotive Marysville, MI on contract to solve issues regarding processing of tubular products and barrier hose. These included de-lamination of the hoses and rupturing of the tubing during pressure testing. Working with TI engineering and the production team to identify the root causes of the failures and possible corrections. We test these potential fixes and implement and document these fixes that worked. We conducted training in these methods for the production teams. With production and maintenance group support developed PM program to maintain equipment to so that they were kept process capable.

Wagon Automotive Wixom, MI 10/2006-12/2007

Manufacturing Engineer

Plant closed

Lead process improvement projects. Responsibilities included equipment specifications, plant layout, process flow, material selection, material handling, automated assembly, tooling, quality controls, capital equipment request and justifications. I also worked successfully to increase equipment utilization and setup PM programs. Processes used were roll forming, CNC bending, stamping and welding.

Acted as the cost estimator for two new products for Ford.

Bartech (Contract House) Bingham Farms, MI 7/2006-10/2006

Quality Engineer 12/2007-6/2009

Contract ended

Worked in various contract positions at three automotive suppliers. Responsibilities include plant layout, process flow, in-process material flow, ergonomic issues and process improvements.

Worked at Chrysler for 1-1/2 years as a Supplier Quality Engineer based at the Auburn Hills Technical Center. Responsible for the APQP process for HVAC systems including fans, shrouds, control heads and temp sensors. This includes working with vendors, engineering and production to track process on the part from design through production. Tracking progress to schedule, conducting meeting with the product team, performing run@rates and conducting PSO and PPAP’s.

Hughes Mfg Div, Tesma/Magna Corp Farmington Hills, MI 11/2002-6/2006

Plant closed refused transfer to Ohio

Manufacturing Engineering Manager

Responsibilities include managing the APQP process for Manufacturing, managing eight engineers with one supervisor, the prototype shop with one supervisor and two toolmakers and the 6-man maintenance group

As part of cross-functional team Six Sigma tools such as DOE & analysis of variation plus other tools such as Design for Manufacturing/Assembly, 5S, 8-D’s, Lean Manufacturing, VA/VE; Value Stream Mapping, Kaizen events, quality & process control methods are used to facilitate continuing improvements and to reduce costs and improve quality. Used such methods as DMAIC, Kepner-Tregoe and 5 Whys to root cause a problem and use lessons learned to prevent repeat them.

Worked with all groups at Hughes/Magna to direct the implementation of the Toyota Production System at our manufacturing plant. This included standardized and balanced workload in the cells reducing/eliminating overproduction, WIP, waiting, scrap and excess material movement.

Provided support and direction for the manufacturing group for the successful launch of one fuel tank & four fuel system products for Chrysler and one for GM. Responsibilities included equipment specifications, plant layout, process flow, material selection, material handling, automated assembly, tooling, quality controls, capital equipment request and justifications. Manufacturing cells were implemented requiring 36% of the floor and 45% fewer operators than previous methods. Savings were $8,700,000 over two years.

Led team that implemented a JIT production system.

Worked as part of a four-person team to develop costs, processes improvements, equipment specifications and capacity planning for new products at a sister division producing forgings for engine cradles and for transmission coupling.

Leading a cross-functional team including potential vendors we worked to implement the use of new technologies including stamping, deep draw forming, hydro-forming and welding of thin wall stainless steel tubes, fuel tanks and other high volume automotive products and to direct the implementation of the Toyota Production System

Mark IV Automotive Detroit, MI 9/1997-10/2002

Project Engineering Manager

Recruited by Magna

Managed a group of seven engineers, three tool makers and two supervisors, responsibilities include managing the APQP process and lean manufacturing implementation for Manufacturing Engineering and managing the development & prototype shop.

Employed as Project Engineering Manager with Mark IV Automotive a Tier 1 automotive supplier of fuel systems, my team worked with the Program Management Teams for DCX, GM, Isuzu, Toyota and participate in the development of and execution of the DVP&R, Design and Process FEMA’s. Worked with the customer teams to optimize the design and improve manufacturability. Worked with all groups at Mark IV and our suppliers to direct the implementation of the Toyota Production System at both manufacturing plants. This included standardized and balanced workload in the cells reducing/eliminating overproduction, WIP, waiting, scrap and excess material movement. Mentored continuous improvement teams in the two plants

Introduced cellular manufacturing and lean manufacturing methods with Statistical Process Control to replace a batch manufacturing system that was inefficient and produce poor quality components. After installation of the first cell quality improved by 75%, output increased 60% and manpower requirements decreased by 50%. Work in-process was decreased by 60%. For the Chrysler product lines PPM’s went from 700 to 30 in three years. These cells used vision systems, stampings, laser cutting, assembly, robotic material handling and welding systems. These cells were extended to cover 95% of the production in two plants with a sales volume of 575 million dollars.

Manufacturing cells were implemented requiring 40% of the floor and 50% fewer operators than previous methods. My last year’s savings were $3,250,000, previous year were $2,625,000. As part of our lean manufacturing efforts we initiated value stream mapping of our processes and continuous improvement classes were conducted at our facilities and selected suppliers. Savings realized were split between Mark IV and their suppliers. Developed PM programs the new equipment to improve uptime and increase throughput.

Served as the Program Manager for the parts used on the Jeep Liberty & the GM Envoy/Trailblazer responsible for design, vehicle testing, project management & customer liaison for 1-1/2 years due to manpower shortages.

Information Management Associates Shelton, CT 9/1993-8/1997

Project Manager Excessive travel – Family issues

For three years I was employed as a consultant and project manager in a software development company. Projects ranged from banking and commercial to manufacturing, my responsibilities included project management, costing and technical leadership for up to ten programmers and analysts.

Completed a project for Pacific Gas & Electric in San Francisco, CA that consolidated twenty-four customer service centers into four.

Worked on a customer help line system for a large insurance company, whereas Programming Leader I was responsible for software development and testing. Response time was reduced by 50 percent; completion of query on first call was increased from 65 percent to 97 percent.

Successfully completed a project to build a user-friendly interface for the Phillip-Morris ERP system

Worked on a Washington D.C. based Account for the Public Broadcasting Corporation to install an order entry system, where as Project Manager I was responsible for software development, hardware integration and training. Order accuracy increased to 99.9 percent.

D-M-E Division of Cincinnati Industries Madison Heights, MI 1/1982 – 9/1993

Manufacturing Systems Engineering Manager Recruited by IMA

Reporting to the Director of Operations, I developed, trained and managed an advance manufacturing systems group consisting of seven engineers and two CNC programmers. We provided manufacturing and processing engineering support to our six plants. D-M-E was at the time the largest producer of tooling for the plastic injection molding and die casting industries. We maintained a lab with 11 molding and casting machines.

As a team we developed and helped implement a computerized system for estimating time, scheduling and cost for all our special machining in production of injection molding and die cast tooling. This required analysis of all processes and operations which were optimized and standardized so that we could develop programs that were accurate and repeatable. An additional benefit was consistent pricing and more precise scheduling of

D-M-E’s non-standard tooling manufacturing at the company’s four plants. Quote turnaround time was reduced from 6 days to 1.5 days on average. Served as the manufacturing representative on the ERP implementation team.

Worked closely with the product design teams to test and optimize new products for the injection molding and die casting industries and to create processes to machine for and install components.

Worked with the product & marketing groups to develop and test new molding products and processes. Worked with SDRC and CADKEY to develop a set of CAD design and CNC programming software systems to be used internally and marketed to the mold making industry.

The group completed several projects to implement JIT manufacturing in the four special machining plants. These include the installation of flexible manufacturing systems, new plant layouts, new tooling, metal working processes, modular fixturing and advanced control methods. We were responsible for specifications and selecting equipment and tooling. Results show a 50 percent reduction in build time and a 45 percent reduction in direct labor hours. Used HB Maynard’s MOST and MTM methods at all my employers. For the machining of injection molding and die-cast tooling CNC mills, machining centers, various grinders and deep hole drilling machines were used. Normal working tolerances for milling or boring was +/- .001 & best tolerance +/- .0005.

Also, I worked at D-M-E for over 4 years as an Estimator, quoting special machining from customer prints. This included costing of machining operations, scheduling, developing a BOM, tooling & process flow.

Experience with: Windows based PC's, Quality Systems, ERP, CAD & CAM software, “C+” programming language; MS Office, Signal for Statistics and MS Project.



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