Jim J. Glusic

**** * *** *

Rossville, IN *****

765-***-****

www.linkedin.com/in/jim-glusic/

EMPLOYMENT OBJECTIVE

To apply professional mechanical assembly, design and test automotive components experience in Lean

Manufacturing Engineering field to produce world class quality products. Ready for Mechanical

product design position.

QUALIFICATIONS SUMMARY

Provide strong mechanical aptitude leadership as Lead Manufacturing Engineer for new advanced program teams. Provide advance planning, problem solving leadership and knowledge of

manufacturing processes on multiple +$2 Mil GM North America Powertrain Engine Control

programs and Aftermarket Controller- Mexico Site

Provide Lean six sigma Manufacturing Process Flow and Quality Plan details APQP, SPC

requirements working with Operations Engineers, Industrial Engineering and cross functional

teams.

Lead new high volume Friction Stir Welding equipment procurement implementation launch

and debug thru SOP

Capital equipment design and implementation plans using Lean Manufacturing six sigma

techniques.

Follow Delphi procedures for ISO 9001/TS6949 company quality requirements for all

manufacturing items.

Planning for high volume process assembly and test equipment and tooling for high

technology high volume manufacturing and low volume prototype/ validation builds. Provide

capability studies and strain measurements.

Provide design for manufacturing DFM and stack up of tolerance details to Product

Engineering.

Provide design detail inputs for new product design.

Resolve validation design issues in product design cycle.

Lead identification and problem solving of prototype products regarding processing, quality

and design issues, customer issues through high volume 1st year start up including design

validation testing phases, PPAP, Process Validation, and Run at Rate phases using Six Sigma

tools, Lean Manufacturing training tools and statistical tools.

Write Statement of Work documents for purchase on new standard assembly /test

equipment, vision systems inspection equipment and Tooling concepts documentation for

tool design activities including new advanced Friction Stir Welding process and SPC pull

testing equipment.

Provide management complete PFMEA documentation and timely updated as

owner/originator.

Develop and implement new standard high volume production improvement processes

across multiple sites. Lead Standardization and implementation capital equipment and

tooling at multiple mfg. sites.

Provide Manufacturing Engineering lean principles to Industrial Engineering’ s multiple

Manufacturing Systems Design MSD workshops to define factory layout reduce labor and

reduce manufacturing costs.

Initiate innovative materials cost savings projects across multiple product lines.

Capability studies, MSA Planning and documentation using statistical process control

methods.

Review product drawings details and BOM for correctness and manufacturability.

Leads debug activities on new major savings processes. Support Operations on existing

production programs.

Write Process Specification documents and work instructions for Operations.

Audits new products and new processes to company workmanship standards using

Metrology data.

Leadership in the area of problem solving new process equipment, warranty, supplier quality

and improvement.

Review and analyze process quality issues and report to management. Provide risk

assessment on new program.

Use advanced materials chemical analysis, stress-strain studies, vibration analysis study

process improvements.

Computer Experience: MS Excel, Word, Auto Cad tutorials, MS Office, Micrographics Designer

EDUCATION Bachelor of Science Mechanical Engineering University of Illinois

Urbana, IL

FORMAL SPECIAL TRAINING

Six Sigma Greenbelt I&CIM DFSS DE, MSD Lean Concepts Education, Mistake Proofing Course, Value

Analysis, Geometric Tolerance, Quality Engineering Course I, II, III, IV, Reliability Engineering Course,

Total Quality Systems, Economic Evaluation of Projects, Methods Engineering at Delco, Purdue

University Classes toward Master’s Degree Industrial Engineering, DOE ANOVA course at Purdue

University

PROFESSIONAL EXPERIENCES/ EMPLOYMENT

Senior Manufacturing Engineer Delphi Electronics and Safety Kokomo, IN

1986 to 3/2013

Design for Manufacture, Develop, Plan, Procure, Install, and debug equipment and tooling of world

class high volume General Motors North America Engine Control Products ISO 9001 company. Lead

Manufacturing Engineer on multiple product/process development Program Teams new products

launch cycle for prototype validation, PPAP, Process Validation, Run at rate, and high volume SOP.

High volume automotive customer and low volume aftermarket product line lean planning and

equipment/tooling procurement and modification at 3 mfg sites. Multiple PFMEA owner, Quality plan

details APQP, capability studies, debug leadership & coordination of new equipment and

Certification with Metrology for ongoing certification. Customer contact person for

process/manufacturing and in-house product quality issues. Launch new + $2 mil ea. GM products

across 3 manufacturing sites. Implement std cost savings innovations at multiple mfg. sites. Plan,

continuous improvement advance processes. Assembly equipment, FSW, dispensing, process ovens,

robotic asm. and testing, soldering, surface mount assembly, mechanical interface testing,

transparent to test equipment, leak testing, lead forming, coating equipment, Share knowledge

across worldwide mfg. sites. Provide methods to suppliers for error proof supplier processes and

debug supplier quality issues at supplier sites. Error proof techniques for family processes.

Provide design inputs to Mechanical Product Engineering. Provide Product design solutions to

validation issues.

Sr. Manufacturing Engineer Delco Electronics division of GM Hughes Oak

Creek, WI 1985 – 1986 Automotive Electronics Powertrain high volume GM

(ECM) process assembly manufacturing engineer, wave solder, auto screw

equipment systems and conformal coat machines. Plan, develop and support

production modules for new products, equipment and tools. Corporate GM

Barcode Committee Coordinator. Support planning and daily production for EFI-

4U, SFI-66U, and PFI-4 engine control products. Trouble shoots quality and

manufacturing process issues. Introduce new quality testing equipment for seal

integrity used across the corporation. Delco Process Center of Expertise leader.

Manufacturing Engineer Delco Electronics division of GM Hughes Oak Creek, WI

1982– 1984

Support Delco Electronics Inertial Instrument products including Gyroscope and Accelerometer,

clean room assembly equipment for Carousel IV Navigation Computer Systems for aviation and

Government Programs, develop new gyroscope

Manufacturing Engineer Delco Electronics division of GM Kokomo, IN

1982 – prior Premium radio planning, processes support and assembly. Provide ROI

calculations on alternatives. Reject Reduction committee, Methods Engineer, Delco Engr. change

team coordinator on ECT committee.

2000 to 2013 RECENT PERSONAL ACHIEVEMENTS:

- Successful launch new E92, E78 ECM +$4Mil product programs for GM powertrain

customer proto/production.

- Successful Savings Program- Friction Stir Weld Technology +$1Mil savings new

process/technology

- Successful Advanced Process Improvement – Friction Stir Welding- Automotive PACE

award finalist 2014

Eliminate product/metallurgy weld distortion new Friction Stir Welding process 2-

2013 +$300k savings

Eliminate burrs in Friction Stir Welding 2012 - Cost savings/avoid +$2 Mill Patent

Review Merit Award

- Successful Implementation of Lead Free Wave Solder and Yield Improvement 2010

Cost Savings- eliminated repair operators/operation $2.1 million life of program

Hughes Materials award

Delphi Shingo Prize Excellence support manufacturing engineering for plants 2004 and

2006- Provide Mfg. Engr. leadership in mfg engr. Process/quality excellence in launch of new

GM products at Kokomo plant 7, 9 and Milwaukee Operations Oak Creek, WI For family of

products including GM NA powertrain products. Error proof Leadership Award 2000.

Benchmark process designation. Published SAE paper on Customer Mechanical Interface

Error proofing. Merit Award - Complex E60 program success. Merit award - supplier quality

solution.

- Greenbelt Certification project: L6 Interposer Contamination Reduction- reduces

interconnect electrical contact fails 2003 Cost Savings Estimate $80k repair labor

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