Engineer Project Manager
Resume:
JOHN G. HOWE
Columbus, MS *****
*******@***.***
SUMMARY OF QUALIFICATIONS
Thirty years of engineering, quality, product design & development and
project management experience in automotive systems and components,
commercial / consumer mechanical & electro-mechanical products and
components from concept development through production launch and post
launch product support.
. Twenty two years of automotive experience including fourteen years
working directly for or supporting OEM or Tier 1 companies such as
Chrysler, Arvin Industries, Visteon, Nissan, Janesville Acoustics,
Eaton, Ford, General Motors and Borg-Warner Automotive.
. Eighteen years of increasing management responsibility in both
engineering and quality including over three years at the Director /
VP level.
. Fifteen years with injection molded product design, development and
support.
. Fourteen years of practical hands-on experience in quality management
and product support in ISO 9001 / QS 9000 / TS 16949 manufacturing
environments including involvement with and AIAG training in FMEA,
Control Plans, APQP, PPAP, SPC, MSA, GD&T and QS9000 / TS 16949
requirements and procedures.
. Eleven years of experience in steel fabrication, weldments, stamping,
machining and other steel processing.
. Ten years of experience in automotive interior trim systems and
components.
. Extensive involvement and experience working with customers and
suppliers on a variety of projects including product containment,
development, support; cost reduction, and quality issues, product
documentation and packaging issues.
. Experience with developing and improving documentation control
procedures and quality systems in conformance to ISO 9000 / QS 9000 /
TS 16949 quality standards.
. Knowledgeable of Lean concepts and experienced using 8D & PDCA / A3
problem solving methodology.
. Knowledge and understanding of composites, compression formed,
extruded and vacuum formed plastics, and automotive non-woven carding,
molding and water jet cutting of non-woven formed interior soft trim.
. Experience and knowledge in mechanism design, DC motor control, DC
motors, AC linear actuators, precision rollers, wood & laminated
products, PVC belting, Rapid Prototyping methods such as SLA and
rubber molds,, electronic wiring, automotive exterior trim &
lighting, and radiators.
. Performed system design & engineering analysis including drive system
analysis, flywheel design, bearing analysis, weld analysis, steel
fatigue and life structural analysis, and drive belt life analysis.
. Experience in transitioning operations to and from new facilities
including the transfer and setup of new prototyping and testing
facilities, and cost justification, analysis & quoting for the
outsourcing of stamping, machining, and heat treat operations.
. Budgetary responsibility up to $1.5 M.
PROFESSIONAL EXPERIENCE
Apr 2014 to Present - Janesville Acoustics - Quality Manager, Columbus, MS
. Responsible for a team of one Quality Engineer and three
Quality Techs supporting a 3 shift 5 to 6 day per week
operation.
. After assuming responsibility for TS 16949 compliance and
acting as both the Quality Manager and Quality Engineer for
the plant, successfully implemented effective corrective
actions to address 7 non-conformances (3 majors & 4 minors)
within 90 days to remove our TS 16949 certificate from
suspended status. This involved an additional 12 non-
conformances that were previously not addressed from three
previous quarterly internal audits.
. Implemented a new reject review process that improved the
accuracy of reported rejects from less than 70% to 98% within
30 days.
. Lead the effort to initiate and implement PDCA / A3 focused
problem solving methodology using cross functional teams to
address the top CAPA issues within the plant.
. Drove internal containment costs from $18K per month to less
than $4K per month while maintaining low external sorting
costs and high customer satisfaction.
. Currently responsible for launch management and PPAP
activities for two new Chrysler programs, LX (300) and RU
(Minivan) underbody systems as well as the new Nissan L42N
(Maxima) program adding over $30M of new business.
Oct 2013 to Apr 2014 - Janesville Acoustics - Quality Engineer, Columbus,
MS
. While responsible for internal Safe Launch and containment
efforts, monthly external sorting costs dropped from $8K to
$10K down to zero for 7 straight months, and increasing to
$1500 once in the following 4 months while customer
satisfaction improved, as measured by our monthly scorecards,
to the mid and upper 90% level for Ford, Nissan and Chrysler.
. Using data from Safe Launch activities, we drove 1st pass
defects down below 3% for the L42C program.
. Managed the rework of over 5000 L42C Trunk Side parts while
simultaneously protecting the customer with our Safe Launch
efforts resulting in zero defective product reported by the
customer of these parts. This effort was necessary until we
were able to produce our own blank material which resolved
the issue.
. Successfully launched and PPAP'd the transfer of the Nissan
L42C (Maxima) Trunk Sides and Wheel Liners to our plant.
. Successfully launched and PPAP'd the new Tesla RHD Electric
Vehicle Carpet Floor and Dash Insulator program.
. Managed all PFMEA, Control Plan, Process Flow and Work
Instruction documentation for Nissan L42L (Altima) & L42C
(Maxima), Ford Fusion, and Chrysler Jeep programs produced in
the plant.
Jan 2013 to Oct 2013 - Janesville Acoustics - Contract Quality Engineer,
Columbus, MS
. Provide contract Quality Engineering support for launch of
Nissan L42L (Altima) program including creating Process Flow,
PFMEA and Control Plan documentation for PPAP process.
. Conducted Gage R&R studies on all check fixtures for L42L
program.
. Assisted with creation of SOP's and work instructions to
support L42L program.
. Assisted with the implementation of standards and procedures
to support TS 16949 initial registration efforts.
2004 to Present - PSS & QRS - Owner / Project Manager / Customer Quality
Engineer, Columbus, MS
2003 to 2004 - The PIC Group - Project Manager, Canton, MS
Quality related support and containment services to the Automotive
Industry.
. As the owner of PSS, I successfully recognized the changing
market conditions in the automotive industry in 2006, with
slowing industry sales projection and slowing receivables and
increasing rumors of bankruptcy from our customer base, I
took decisive action to significantly reduce our exposure and
eliminated over 80% of our product sorting and containment
activity laying off all but a key group of employees. This
team focused on providing customer liaison / customer quality
engineering support for several key accounts (Tier 1 / Tier
2) with the ability to rapidly respond to stabilize a product
quality issue on-site until a localized 3rd party containment
provider could take over those activities for the longer
term. After which I would continue to manage the containment
activity on behalf of my client and serve as the liaison to
the end customer often taking part in the corrective action
activities. This change in strategy has allowed the company
to survive to this day providing high quality rapid response
containment services to key automotive suppliers in AL and
MS.
. Maintain open and direct communication and dialogue with
clients and end customers regarding quality defect levels on
containments using various quality reports, tools, charts
(Pareto, Histograms, SPC, Control Charts, DOE, 8D, 5Y, PFMEA,
Process Flow, PDCA / A3) and methodology in accordance with
APQP quality standards.
. Responsible for managing multiple projects across various
geographic locations which included managing up to 50
employees and providing product containment services and
quality engineering support to various automotive suppliers
located in AL and MS who serviced the Nissan plant in Canton,
MS and the Mercedes plant in Vance, AL.
. Assist in determining root cause for product quality issues
and implementation and management of containment and
corrective actions at the plant level utilizing SPC, FMEA,
DOE, APQP, 8-D, and PPAP methodology and tools.
. Responsible for sales and marketing efforts to build the
business with various automotive suppliers in the regions of
MS & AL for our product containment and engineering support
services.
2002 to 2003 - The PIC Group - Supplier Quality Engineer - Lextron /
Visteon, Canton, MS
Quality related support and containment services to the Visteon VRAP
facility at the Nisan Plant..
. Coordinate and support incoming product quality issues to the
plant from dozens of external parts suppliers.
. Assist in determining root cause for product quality issues
and implementation and management of containment and
corrective actions at the plant level and supplier level
utilizing SPC, FMEA, DOE, 8D, Control Plans and PPAP tools
and methodology in accordance with the existing APQP system.
. Maintain open and direct communication with suppliers
regarding quality related issues on their product.
. Support production lines with quality related issue to
minimize impact to production.
. Support VRAP Quality Dept. with product quality related
issues.
2000 to 2002 - AETNA BEARING COMPANY, VP - Engineering & Quality, Chicago,
IL
Leading manufacturer of automotive and agricultural bearing assemblies.
. Lead the efforts of the Engineering, Quality, Production
Control and Purchasing Departments.
. Managed thirteen people, an operating budget of $500K, and a
capital budget of $250K.
. Supported $3M stamping operation & tool room which included
12 presses from 60T to 600T and stock thickness from .040" to
.280".
. Performed complete engineering analysis and cost
justification for outsourcing the heat treat, screw machine
and stamping departments totaling over $3M in outsourced
business.
. Maintained the QS9000 Quality System to assure compliance
with existing standards including rewriting and
implementation of quality policies and procedures.
. Revamped the engineering documentation system to improve ECN
efficiency, accessibility, and accuracy.
. Implemented and staffed a major project to review and revise
all drawings, BOM's, routings, and other documentation for
accuracy and completeness.
. Managed the successful launch of a redesigned clutch assembly
for an agricultural seeding unit for improved performance.
. Managed a critical project, for our largest customer, to
provide twenty-five corn-head idler sprocket prototypes, of
various designs, in less than 30 days. These sprocket designs
included both plastic and steel alternatives.
. Resolved a major warranty issue, on our highest volume clutch
release bearing, by identifying the root causes and
implementing manufacturing process changes as well as short
and long term design modifications to improve the integrity,
manufacturability and profitability of that product.
1999 to 2000 - SAFETY-KLEEN, INC. - Director - Product Engineering, Elk
Grove Village, IL
Leading environmental services equipment and service provider.
. Lead the efforts of a team of fourteen engineers, designers,
and technicians towards the development of parts cleaning
equipment, water processing equipment, and other types of
environmental cleaning and processing equipment.
. Spearheaded an effort to streamline the engineering release
process to improve both the turnaround time and the
information communicated during the documentation process.
. Eliminated the practice of releasing products without
adequate testing and development which was draining the
company's resources.
. Stabilized the team's manpower by quickly filling six (6)
open positions and preventing two (2) pending resignations.
1998 to 1999 - UNIVERSAL FITNESS - Director - Research & Development, West
Point, MS
Manufacturer of consumer fitness equipment.
. Responsible for the development of both product and systems
for this new division of Flexible Flyer Acquisition
Corporation including oversight of the $1.5 million R&D
budget, establishing a new 25,000 square foot test facility,
supervising the prototype shop, and managing 11 designers,
engineers, and technicians.
. Implemented a product development process, drawing standards,
ECN controls system, BOM system, P/N system, testing
standards, and design philosophy which were all ISO 9000
compliant.
. Successfully launched three treadmill models in a less than
ideal environment, and initiated the development of two new
treadmill platforms and an outside R&D project to develop a
composite treadmill platform.
1997 to 1998 - CHAMBERLAIN GROUP - Senior Project Engineer, Elmhurst, IL
Leading manufacturer of consumer and commercial garage door openers.
. Responsible for leading the development efforts on the
tubular rail project for the new BDC product line of garage
door openers.
. Directly involved with development of the roll-form process
for the tubular rail as well as the design validation of a
swaging process for a rectangular tube.
. Coordinated all testing activities for the rail project as
well as the build-up and installation of over 300 field units
across the country.
1991 to 1997 - LIFEFITNESS - Franklin Park, IL
Leading manufacturer of consumer and commercial fitness equipment.
Project Manager - Treadmill Development (September 1993 to May 1997)
. Responsible for new product development for both the
commercial and consumer market. This included the successful
launch of the TR3500/TR4500 consumer treadmill platform, the
redesigned TR5500 consumer treadmill and the TR8500
commercial treadmill and initial concept development of the
new TR9000 series commercial treadmill.
. Responsible for the support of existing commercial treadmill
products such as the TR9000 and TR9500.
. Responsibilities involved project planning, scheduling,
budgeting; directing the activities of a team of designers,
engineers and technicians, and coordinating all testing
activities for both field and in-house testing.
. Maintained close interface with other departments such as
Marketing, Purchasing, Manufacturing, Product Support, Sales,
and Accounting to insure the technical excellence of the
product and the success of the project.
. Successfully developed strong working relationships with key
vendors in the industry. These relationships led to jointly
developed new products and provided early access to new
technology and/or products developed by the vendors.
. Duties included a significant amount of engineering and
analysis work during the heavy design phases of the project.
Senior Mechanical Engineer / Project Leader - (1992 to 1993)
. Instrumental in bringing the companies first consumer
treadmill to production on time and under budget. The TR5500
was well received by the market and received high ratings in
Consumer Reports. First year warranty claims were below 1%.
. Engineering responsibilities included the design,
development, and analysis of various mechanical components
such as bearings, shafts, structural plastic components,
steel weldments, drive & conveyor belts, pulleys, and
hardware. Worked with injection molded and sheet molded
plastics, steel tubing, sheet metal, and wood products, as
well as various elastomers.
. Developed test plans for field testing and lab testing and
supported all testing activities.
Senior Mechanical Engineer (1991 to 1992)
. Responsible for the development of feasibility models for a
band-brake load device for bike and climber products.
. Developed mathematical design models to determine performance
characteristics and built actual working models to evaluate
performance. These models were the foundation for the
development of an eddy current load device which was used on
the LS5600 stair climber and the LC3500 aerobic trainer.
. Developed a working model of a total body ski machine for
preliminary product evaluation and review.
1990 to 1991 - ARVIN INDUSTRIES (Gabriel Ride Control) - Project Engineer,
Carol Stream, IL
Leading manufacturer of automotive suspension components and systems.
. Supported the development activities on the Adaptive
Suspension system for the 1995 Ford Explorer in the prototype
concept and production readiness phases.
. Developed computerized project plans, project presentations,
budgets and resource plans.
1987 to 1990 - BORG-WARNER AUTOMOTIVE - Product Engineer, Bellwood, IL
Leading manufacturer of automotive transmission components.
. Responsible for supporting over $5 million worth of One Way
Clutch business with Ford and General Motors..
. Responsibilities included failure analysis, product
development, and product support for Ford and General Motors
product lines. Interfaced regularly with Engineering and
Purchasing personnel to maintain open communications and to
make sure the product and customer were supported adequately.
. Developed strong working relationships with internal factory
personnel to resolve problems quickly and efficiently.
1984 to 1987 - CHRYSLER CORPORATION - Detroit, MI
Automobile manufacturer.
Product Development Engineer
. Held initial assignments with the Manual Transaxle Group, Engine
Development Group, and the Vehicle Dynamics Group supporting their
product development efforts.
. All assignments involved the design, development, and testing of
automotive components and systems. A majority of my time was spent
with the Manual Transaxle Group developing a new 5-speed manual
transmission system.
. Developed a great working relationship with the design group,
manufacturing personnel, lab technicians, management, suppliers and
peers.
EDUCATION
. Bachelor of Science in Mechanical Engineering (BSME), 1984
University of Illinois, Urbana/Champaign, Illinois
. Master of Business Administration (MBA), 1992
DePaul University, Chicago, Illinois
. Certificate in Project Management (CPM), 1996
DePaul University
. AIAG training in FMEA, DOE, Control Plans, APQP, PPAP, GD&T and
QS9000, 2001.
. Nissan / M-Tek Supplier Training - PPAP / Problem Solving & Capacity
Management measurement & documentation requirement for new programs.
AWARDS
. Delta Mu Delta & Beta Gamma Sigma, National Honor Societies
DePaul University, 1992
. Received appointment to US Naval Academy, Annapolis, MD - 1979
SKILLS
. Currently pursing my Six Sigma Black Belt Certification with targeted
certification within six months.
. Self taught on Lean concepts, principals and methodology
. Skilled in PDCA / A3 problem solving methodology utilizing 5Y root
cause analysis, Ishikawa-Fishbone diagrams cause analysis and A3
reporting.
. Highly proficient with most Windows based software applications
including Word, Excel, Project, Powerpoint and Access.
. Understand GD&T
. Excellent problem solving, communication, and interpersonal skills.
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