Allen G. Renfrow Jr.

**** ***** **** *****

Fort Wayne, Indiana 46845

Home: 260-***-**** Cell: 260-***-****

acp89n@r.postjobfree.com

PROFESSIONAL SUMMARY

Global Product Development / Senior Engineering Leader with 18 years of experience comprised of 8 years in product development and 5 years each in engineering and manufacturing management. Proven leadership demonstrated by the ability to deliver mission-critical programs and product launches through cross-functional teams supporting a variety of business units. Successful launch of large programs utilizing multi-national teams for design, development and validation. Experienced in leading multiple projects, driving results, directing suppliers and vendors, in addition to, developing individuals to effectively lead teams, exceed expectations, and embrace change. Multi-site process and procedure commonization and standardization, and harmonization. Proficient in the use of quality (VAVE, Lean and Six Sigma) and failure prevention tools and methodologies (DFMEA, PFMEA, APQP, PPAP, ISDM and PSDM). Areas of expertise include the following:

Engineering Management

Cross-Functional Leadership

International experience

Program Management

Project Management

Product Design

Product Development

Product Validation

Product Launch

Advanced Manufacturing

Manufacturing Process Optimization

Product Tooling

Injection Molding

Stamping

SIX SIGMA Methodologies

Process Development and Improvement

Body Systems Engineering

Chassis Systems Engineering

Powertrain Systems Engineering

Benchmarking

Program Finance and Budgeting

US Patents

PROFESSIONAL EXPERIENCE

Symmetry Medical Corporation – Avilla, Indiana April 2013 – Present

Engineering, Quality, and Regulatory Affairs Manager

Manufacturing Engineering, Quality Assurance, Production Engineering, Regulatory, and Product Development

Reporting to the General Manager and matrixed to the Director of Quality and Regulatory Affairs, responsible for manufacturing and production engineering along with facilities, purchasing, process planning, quality, and regulatory affairs. Lead a team of 7 Manufacturing Engineers, 3 Quality Engineers, 9 Auditors, 4 Process Planners, 2 Materials Associates, Tool Crib Attendant (Tool Setter), Inventory Control Coordinator, Toolmaker, and Engineering Purchasing Manager. Leadership of initiatives including: site to site process harmonization, program management, industrialization of new products, scrap reduction, cost efficiency and quality improvements, product line moves, perishable tooling standardization, lean implementations, machining process improvements, and ERP management system improvement initiatives.

Investigated, planned and implemented $342,000 in cost savings and avoidances resulting in improvements to ROI, safety, quality and manufacturing processes in first year.

Increase throughput using cellular concepts by 63% while delivering 44% productivity (cycle time) improvement.

Introduced product development and launch process for new product development and industrialization.

Reengineered facility layout improving ergonomics, flow and freeing 8,000 sqft of floor space.

Reconfigured multiple lines and revised plant layout to embrace lean manufacturing, one-piece flow, and a visual production environment.

Developed and launched a new production cell to accommodate several different styles of bone plates shortening lead-times and improving product quality delighting the customers by exceeding their expectations in both cost and timing.

Developed and led initiative with other members of the management staff to increase the facility gross margin.

General Products Corporation – Angola, Indiana Jan 2012 – April 2013

Engineering Manager

Manufacturing Engineering, Production Engineering and Product Development

Reporting to the Plant Manager and matrixed to the CEO, responsible for manufacturing and production engineering along with facilities, purchasing and Environmental Health and Safety. Lead a team of 6 Manufacturing Engineers, 3 Engineering Technicians, 3 Tool Crib Attendants (Tool Setters), Facility Engineer, Inventory Control Coordinator and Engineering Purchasing Manager. Leadership of initiatives including: program management, industrialization of new products, scrap reduction, cost efficiency and quality improvements, product line moves, perishable tooling standardization, lean implementations, machining process improvements, Environmental Health and Safety and ERP management system implementation initiatives.

Investigated, planned and implemented $1.38M in cost savings and avoidances resulting in improvements to ROI, safety, quality and manufacturing processes in first year.

Increase capacity of Clutch Housing line by 56% while delivering 71% productivity (cycle time) improvement.

Increase capacity of Upper Control Arm line by 41% while delivering 37% productivity (cycle time) improvement.

Introduced Voice of the Customer process for new product development and industrialization.

Reengineered facility layout improving ergonomics, flow and freeing 23,000 sqft of floor space.

Reconfigured multiple lines and revised plant layout to embrace lean manufacturing, one-piece flow, and a visual production environment.

Developed and launched a new production cell for a transmission extension in 9 weeks exceeding customer expectations in both cost and timing.

Reduced labor related PPM by more than 35%

Reduced Total Recordable Case Rate (injuries) by 27% in one year.

Crown Equipment Corporation – New Bremen, Ohio 2011 – 2012

Senior Advanced Manufacturing Engineer – Counterbalanced Products

Advanced Manufacturing Engineering – Product Development Group

Provided expertise and collaborated in the development and launch of a new internal combustion truck.

Worked with the Engineering Group to develop, refine and launch new product offerings for electric counterbalanced trucks that included injection molded, forged, cast, stamped and welded components.

Hypersonic Technologies Corporation - Fort Wayne, Indiana 2009 – 2011

President, Engineering and Partner

Engineering and Manufacturing Solutions

Directed and oversaw all aspects of engineering and business operations. Develop financial targets, agreements and partnerships both internally and as a service to our clients. Led the Engineering Group in the design, development and deployment of mission critical customer projects and programs. Established and set priorities for resource allocations insuring the timing, completeness and accuracy for all customer projects meet expectations. Supervised a staff of up to 17 engineering, software and failure prevention professionals.

Provide expert technical and engineering development solutions to a global OEM in support of the development and launch of their production electric vehicle.

Assist clients in supplier development as well as identifying full service suppliers.

Compile engineering statements of work in order to accurately assess new projects and opportunities.

Develop engineering, prototype, test, analysis and validation estimates for project and program creation.

IT Infrastructure and Web Site Development

Database Development, Consulting & Support

Custom Application Development

Lead the sales efforts for engineering, technical and advanced technology services along with manufacturing, quality and sourcing services.

Develop comprehensive computer based training courses for a major insurance provider (The Harford).

(Formally Exited Operations June 2011)

International Truck and Engine Corporation (a Navistar Company) 1998 – 2009

Sr. Program Manager – Fort Wayne, Indiana 2008 – 2009

Global Electrical Engineering Systems – Idle Reduction Solutions

Responsible for the launch of the “MaxxPower” Idle Reduction System. Lead design, prototype, test, analysis and validation efforts culminating in a successful product launch. Provide leadership to a team of 5 Product Design and Validation Engineers along with Tier 1 and Tier 2 suppliers and a worldwide OE network. Led prototype, validation builds and manufacturing implementation at International assembly plants.

Directly interface with prospective and active customers as the point of contact for International Idle Reduction Solutions

Lead program efforts to complete product, system, component level designs and interfaces with the vehicle.

Provide reports to upper management including company President, General Manager, Vice-Presidents and Directors.

Additional responsibilities include: Budget development, program accounting and reporting, directing outside engineering resources, and management of direct reports

Sr. Program Manager /Interim Director – Fort Wayne, Indiana 2007 – 2008

International Engineering Solutions – Fast to Market Applications

Promoted to this position reporting to the Vice-President of Global Engineering and Product Creation, member of a leadership team tasked to start a new LLC for Navistar charted to provide engineering, validation and program management services to companies outside the Navistar umbrella. Developed strategic plan, resource plan, operating agenda, and budget ($1.2M) for the group. Provide continual leadership for International Idle Reduction Systems while directly interfacing with prospective IES customers in order to establish the new company’s presence in the market. Develop estimates and proposals for customer engineering, prototype, test, analysis and validation projects. This role included the management of 9 Product Design and Validation Engineers along with worldwide OE network. Led prototype and validation builds.

Act as the “Voice of the Customer” on projects assuring their needs and requirements were present in the finished product.

Coauthor and present grant documentation resulting in receiving funding from the Department of Energy (DOE) and Environmental Protection Agency (EPA) for $1.2M towards the development of the new auxiliary power system.

Coordinate and lead Project Engineers to develop product assumptions, system requirements, component level designs and interfaces for customer specified projects and applications.

Assure programs meet customer, engineering, styling, timing, validation and financial targets.

Provide ongoing business assessments and status reports to upper management including company President, General Manager, Vice-Presidents and Directors on the performance of the entity.

Additional responsibilities include: directing internal and external engineering and validation resources.

(Navistar formally ceased operation of IES in April 2008 after change in leadership)

Sr. Engineering Program Manager (Special Assignment) – Fort Wayne, Indiana 2006 – 2007

Global Engineering and Product Creation – Idle Reduction Solutions

Reporting to the Vice-President of Global Engineering and Product Creation, responsible for the research and develop of local, national and global supply base for International Idle Reduction Systems while directly interfacing with prospective and active customers to assure their needs are incorporated into the product. Develop business case and program charters for program inception and approval including develop of engineering, prototype, test, analysis and validation estimates. This role included the management of 7 Product Design and Validation Engineers along with Tier 1 and Tier 2 suppliers and a worldwide OE network. Led prototype and validation builds.

Managed a $3.5M global product development program that required collaboration with members of 11 companies based in 10 different countries located on 4 continents (Asia, Europe, South America).

Responsible for engineering, styling, timing, validation and financial targets.

Develop design specifications, statements of work, DVP’s, Bill of Material's, DFMEA’s and process validation for No Idle Systems Engineering programs.

Received 1 worldwide patent and additional patents are pending.

Additional responsibilities include: Budget development, program accounting and reporting, directing outside engineering resources, supplier management and the management of direct reports.

Product Development Engineer – Fort Wayne, Indiana 2005 – 2007

Chassis Engineering - Heavy Product

The responsibilities of this role included the management of 18 Product Design Engineers along with Tier 1 and Tier 2 suppliers and a worldwide OE network. Leadership of Program and Project Team meetings and the design, release and implementation of brake, fuel, frame, suspension, axle, powertrain, cooling, exhaust, steering, tire and wheel product designs and enhancements for all Heavy Vehicle applications. Lead the development of design specifications, statements of work, DVP’s, DFMEA’s and process validation for Chassis Systems Engineering programs. Led prototype vehicle builds and manufacturing implementation at International assembly plants.

Developed the engineering budget (2.5M annually) for Chassis Engineering Systems, Heavy Product.

Established an Engineering Release Readiness system that included a scorecard, master schedule and status versus target progress against major deliverables and milestones.

Launched 3 major truck suspension programs, which met all program timing, financial, quality, and timing deliverables.

Launched 3 major truck brake programs, which met all program timing, financial, quality, and timing deliverables.

Received 1 worldwide patent and additional patents are pending.

Product Development Engineer – Fort Wayne, Indiana 2004 – 2005

Heavy Product Center – Model Year Enhancement

Reporting to the Chief Engineer of the Heavy Product Center, responsible for development of the $3.5M Model Year budget, 10 to 12 annual feature enhancements and develop of continuous improvement ideas for International products supporting the customer, market and business expectations for the Heavy Product Center. Accountable for the leadership and management of 3 Product Development Team Leaders along with Tier 1 and Tier 2 suppliers. Responsible for design, release and implementation of Body, Chassis and Electrical enhancements for Heavy Vehicle projects. Led vehicle builds and manufacturing implementation at International assembly plants.

Led the development and validation, sourced components and launched the American Eagle limited edition vehicle on time (9 months) and under budget ($1.1M).

Launched 2 major and 4 minor programs contributing to a decrease in customer PPM. Launches included introduction of new technologies and platform upgrades.

Exceeded Model Year 2004 weight reduction goal by 14%.

Supplier Tooling Manager, Non-Metals – Fort Wayne, Indiana 1999 – 2004

Purchasing and Supplier Development - New Product Development

Manufacturing Tooling Manager, Castings – Fort Wayne, Indiana 1998 – 1999

Manufacturing Engineering – Manufacturing, Tooling and Technology Development

C & A Tool Engineering, Inc. - Churubusco, Indiana 1994 – 1998

Manufacturing and Engineering Manager 1996 – 1998

Process Engineer 1995 – 1996

Estimator 1994 – 1995

Grant / Durban Engineering, Inc. - Fort Wayne, Indiana 1992 – 1993

Quality Engineer

EDUCATION

Bachelor of Applied Science Degree in Automated Manufacturing Technology (3.9 / 4.0) – September 1995

ITT TECHNICAL INSTITUTE - Fort Wayne, Indiana

Associate of Applied Science Degree in Tool Engineering Technology (3.9 / 4.0) – June 1994

ITT TECHNICAL INSTITUTE - Fort Wayne, Indiana

CONTINUING EDUCATION AND TRAINING

University of Michigan – Ann Arbor, Michigan

College of Engineering – Center for Professional Development

Manufacturing Robotics

Laser Applications

Eastern Michigan University - Ypsilanti, Michigan

College of Engineering – Center for Quality

DFMEA

Design Verification and Production Validation (DV&PV)

Managing Technical Professionals

Global 8D

International Truck and Engine Company - Fort Wayne, Indiana

International University – Miscellaneous Training/Classes/ Computer Proficiencies

Climate for Performance

Coaching for Performance

Advanced Coaching and Leadership

Unigraphics and MicroStation Training

PATENTS AND CERTIFICATIONS

Awarded US Patent for Self Clamping Suspension Member

Awarded US Patent for Exportable Power and Communications Cable

ITAR Certified (International Traffic in Arms Regulations)

BaaN Certified

PFMEA and DFMEA Facilitator

HONORS AND AFFILIATIONS

Finalist for International Chairman’s Award

National Vocational Technical Honor Society

American Design Drafting Association, Chapter Vice-President

Society of Manufacturing Engineers, Member

Society of Plastic Engineers, Section Membership Chairman (1997-1998), Section Vice-President (1998-1999)

Toastmasters

REFERENCES

Furnished upon request

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