Project Manager Engineer

Derek Hunter

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

Ann Arbor, MI *****

Tel: 206-***-**** E-mail: *************@*****.***

OBJECTIVE

Accomplished, highly motivated and results oriented manager and engineering professional with

experience in automotive and aerospace manufacturing, vehicle product engineering, production

systems, plant operations, strategic planning, and project consulting is seeking a challenging leadership

position with an engineering or manufacturing firm.

Available for domestic or international assignment.

SUMMARY

25 years of experience in leadership roles, project management, advanced manufacturing engineering

and product development for both established and start-up commercial manufacturing organizations:

• Automotive – OEM/Tier 1: Manager roles, PM, Advanced Mfg Eng, Tooling, Product Eng,

JIS/JIT, Lean Mfg

• Aerospace – OEM/Tier 1: PM, Advanced Mfg Eng, Tooling, Fabrication, Lean Mfg

Strategies:

• Contributed to performance measurables and budget forecast planning to determine achievable year

over year goals, organizational KPIs and financial targets for sales, EBIT/Cash, operational overhead,

COPQ, customer deliveries and warranty, CapEx equipment and tooling expenditures, development

and project costs, and related corporate metrics.

• Core management team member involved in short and long range business strategy development

and organizational goal alignment. Supported strategy objective planning at all levels of the

organization. Defined benchmark, leadership and group performance metrics, departmental RASIC

definition, organizational goals and objectives, future-state project planning, manufacturing,

production and CapEx financial expenditure strategies to meet projected ROIs.

• Devised strategies to support continuous improvement initiatives in production efficiency, material

and production control, cost reductions, COPQ, training, technical specifications, manufacturing

benchmarks and other areas.

Management:

• Operations Management of automotive and aerospace engineering and manufacturing suppliers.

Responsibilities included planning and executing strategies to meet corporate metrics/KPIs and

financial goals, production operation activities, defining future plant and manufacturing state,

personnel and organizational development, and other activities.

• Responsible for teams ranging in size from 4 to over 200 individual contributors. Managed

professional disciplines including managers, project leaders, engineers (Design, ME, IE, Tooling,

Controls, Technicians, etc), commodity managers, logistics, continuous improvement specialists,

quality, production, maintenance, finance and administration personnel.

• Project Managed complex Tier 1/OEM automotive and aerospace manufacturing/production projects.

Led cross-functional teams, equipment integrators and supply-chain component manufacturers for

multiple manufacturing projects

• Technical lead for AMEs, MEs, IEs, PEs and other departmental personnel for manufacturing process

knowledge.

Technical:

• SME of: Automotive structures, door and roof mechanisms, fabrication and assembly. Aerospace

component tooling and final assembly production systems. Advanced assembly methodologies,

application of manufacturing technology, DFM/DFA/DFP, production and tooling systems, plant lay-

outs, process flows, and integrator management.

2D7mh Page 1 of 7

• Developed innovative manufacturing and assembly methodologies for both automotive and

aerospace production lines including automation, conveyance, mechanical fastening, component

fabrication, and production management systems

Highlights:

• Multi-year Ex-Pat assignment in Germany and the UK.

• Experience with global automotive and aerospace OEMs and Tier 1 component suppliers in the US,

EU, and Asia

• Experience with all aspects of program/plant launches in the US, Canada, Mexico, UK, Germany,

France, Spain

• Webasto: 1-year Milestones achieved: Launch 2 programs (GM, Ford), standardize plant, phase-out

production facility

• Boeing: Managed technical input to determine corporate business case strategy for future

program

• Magna: Launched first Magna Closures JIS/MES “Build to Broadcast” start- up production facility.

• Edscha: Launched first Edscha Roof Systems production facility in N. Am. Greenfield site – Toluca,

MX.

• Brose: Focus “World Car” launch - Managed activities for (2) Brose plants and (4) customer sites

in (5) countries

PROFESSIONAL EXPERIENCE

Sep13 to Current – Webasto-Edscha Cabrio USA Inc – Plymouth, MI

Director of Operations

WEC is a global Tier 1 automotive supplier of retractable soft and hard top vehicle roof systems. The

WEC-Plymouth production facility supplies to multiple US OEMs. Responsible for all WEC-USA daily

production operations and the strategic development of all future-state manufacturing systems,

production process methodologies and operational planning.

• WEC-USA executive team manager responsible for daily production plant operations and WEC-USA

manufacturing strategy for future-state operations. The +100K sq/ft site utilizes a one-piece flow

production methodology that is managed from raw material input to final assembly output utilizing

an SAP/MES production management system.

• Managed (5) direct reports and (200) in-direct reports including IEs, MEs, Continuous Improvement,

Production, Logistics, Project PMs, Plant QEs and Maintenance personnel. Responsible for cascading

corporate goals and objectives and leading to meet corporate measurables. Devised on-going

training plans and strategies for engineers and technical workers. Facilitated engineer exchange

programs with Germany and Mexico sites. Created mentoring programs for core-team members.

Initiated new production colleague and Supervisor pre-training methodologies to reduce time to plant

floor.

• Responsible for a multi-million dollar production facility to meet all operational KPI objectives,

including production targets, environment / health / safety, financials (EBIT, cash), overhead, quality,

OEE, FTT, scrap, equipment budgets and logistics.

• Directed launch of (2) customer programs (GM, Ford) in 2014 meeting program objectives. Oversaw

budget and schedule to meet on-time, on-budget delivery. Both programs currently meeting OEE and

FTT targets. Continuous improvement – Kaizen events, lean activities, 6-Sigma analysis and other

initiatives on-going to improve production efficiency and quality.

• Responsible for providing management direction and SME technical leadership based on strategic

plans for all equipment, manufacturing methodologies, planning and execution of future-state

production strategies. Areas of concentration include DFM/DFA, flexible, turn-key, interactive

assembly systems, MES/SPD/SAP production management systems, digital manufacturing systems,

lean production concepts, in-process QA, work recognition systems, and material/work flows

Sep12 to Sep13 – Boeing Commercial Aircraft - Auburn Tooling Services (ATS) – Auburn, WA -

(Contract)

Senior Project Manager - Technical

2

Derek Hunter

The ATS Division provides equipment fabrication and project management resources for the development

and integration of assembly process equipment and tooling for all Boeing production sites globally.

Responsibilities include project management and technical coordination for production line assembly,

sub-assembly, transport, and component fabrication equipment projects.

• Utilized PMP methods to manage major multi-million dollar sub and final assembly equipment

packages for the 737, 777, and 787 airplane final assembly and component divisions. Equipment

included automated assembly cells, assembly jigs, composite tooling and handling equipment for

wing structures, fuselage sections, engine nacelles, and other components.

• Responsible for managing the coordination and technical aspects of product releases, equipment

design, fabrication activities, resource planning, sourcing decisions, and other tasks required to

support and successfully meet project milestones and objectives. Provided weekly reports to

executive management on KPI progress, RIO summaries, corrective actions and any required “path-

to-green” recovery plans.

• Involved in a strategic business case project for future-state fabrication capabilities and

investment for ATS. Worked directly with executive management on an exploratory project to analyze

ROI for multi-million dollar CapEx proposals.

• Provided ATS project lead and representative support for an exploratory team tasked with

determining the feasibility of proposed new airplane production site planning, required assembly

equipment and processes, logistics, resource investment and allocation and other information

required to support corporate and division future-state planning decisions.

Jun07 to Sep12 – Environ Industries – Seattle, WA

Director of Operations

Privately funded start-up firm specializing in product development and manufacturing integration of

surface coating technologies for automotive, aerospace and consumer components and products.

Executive Manager responsible for providing operational leadership, business and technical support to

internal organizational depts. and customers.

• Responsible for operational activities including engineering, product development, advanced

manufacturing engineering, technology assessments, quality requirements and procedures,

application R&D, supplier development, production equipment specs and standards, contract

negotiations and other related corporate engineering matters. Instrumental in the strategic

acquisition of a key material supplier.

PROFESSIONAL EXPERIENCE

Environ Industries

• Provided operations and technical leadership for strategic planning, budgets, policies and standards,

investor proposals, financial forecasts and sales projections, vendor development, contract

negotiations, and other operations related activities

• Managed (10) direct employees and supplier companies and all related organizational budgets,

contract negotiations, sales support and engineering activities.

• Contributed to annual business planning by defining future growth opportunities, potential business

segments, product market opportunities, and customer sustainability to meet year over year market

objectives essential to securing a positive valuation for the company. Provided customers with

product development and planning to introduce material applications into their strategic markets.

Supported the development of new business opportunities, investment and funding proposals.

Jan07 to Jun07 – General Motors – Warren, MI – (Contract)

Project Manager - Technical / Product and Process Integration Engineer

Assigned to GM’s Metals Fabrication Group (MFG) and Oshawa Assembly Plant to support the (GMX 511)

Global Rear Wheel Drive program. Responsible for confirming Body-In-White (BIW) product engineering

feasibility for manufacture and coordinating the production process for the vehicle sub-components and

final assembly.

2D7mh Page 3 of 7

• Managed manufacturing process, tooling and equipment planning activities for GM – Metals

Fabricating Division (MFG) and Oshawa (production plant) with the global GM Product Development

Team (Australia and US) for all vehicle line outer BIW sheet metal production.

• PDT BIW manufacturing lead (US) and plant representative for BIW component manufacturing

planning.

• Assured that all MFG, Oshawa manufacturing and Global Vehicle Development Process deliverables

were met.

Mar05 to Jan07 - Magna Closures International – Shelby Twp, MI

Lead Advanced Manufacturing Engineer / Project Manager - Technical

Magna’s Vehicle Closures and Modules Group is a global Tier 1 supplier of door module assemblies for

automotive OEMs.

Assigned to the Chrysler JS41 and JS27 Door Module Program - tasked with bringing Magna’s first

JIS/JIT/MES Door Module facility online. Assembly plant was the “benchmark” production site for the

division.

• Responsible for the plant lay-out, product assembly process, manufacturing process, equipment

development, integrator management, equipment build, MES/SPD definition, process flow,

equipment integration and launch of all production systems.

• Managed (6) direct N. Am. and EU equipment integrators and a multi-million dollar CapEx equipment

and tooling budget including P&L tracking and cost-down reduction objectives.

• (4) separate power and free assembly line systems, End of Line Test equipment, sub-assembly work

cells, multi-axis robotic sealant system, part presentation systems and gauges.

• Ensured all systems met Chrysler/Magna requirements for: Overall 85% OEE objective, electrical,

ergo and safety requirements, personnel training, lean and quality manufacturing principles (value

stream mapping, poka-yoke, 5S, mistake proofing, process flow, standardized work, visual metrics,

takt time), FTT, production leveling, line balancing, engineering design standards (DFM/DFA and

PFMEA), run-at-rate SO, customer PPAP and plant production Sign-Off.

Sep02 to Mar05 - Edscha Roof Systems North America - Pontiac, MI

Advanced Manufacture Engineering Manager / Project Manager – Technical

Edscha Roof Systems was a global Tier 1 supplier of retractable soft and hard top systems. Assigned to

Roof Systems Division. Led advanced manufacturing engineering planning and provided technical project

management for a green-field production facility in Toluca, MX to support the Chrysler PT-27 Program.

• Responsible for plant assembly system(s) lay-out and production process definition including:

- Managed (10) production facility engineers and (8) equipment integration companies tasked

with bringing the new ERS “Greenfield” site online in Toluca, MX. First Edscha manufacturing site

in N. Am. - benchmark facility for the company.

- Responsible for plant lay-out, manufacturing process, process planning, multi-million dollar

CapEx equipment and tooling budget, RFQ process, contractual negotiations, equipment

integrators, assembly line equipment development, equipment builds, integration, launch and

SO of all production processes and equipment.

• Developed new manufacturing methods for convertible top product innovations:

- Developed the equipment design and manufacturing process for a patented, “industry first“,

serviceable rear glass.

• Manufacturing Advisor for Edscha hinge-systems division production facilities:

- Developed company manufacturing standards focusing on lean manufacturing systems, (TPS,

value stream mapping, Kanban, poka-yoke) and material flow to improve overall plant efficiency,

cost, and quality.

PROFESSIONAL EXPERIENCE

Dec00 to Sep02 - Oxford Automotive - Troy, MI

Program Manager / Advanced Manufacturing Engineer

Oxford Automotive was a Tier 1 automotive structures stamping company involved in research projects

with the steel industry. Assigned to Closures and/Body Components Group. Responsible for technical

direction and management of a lightweight closures manufacturing research program for OA and the

Auto/Steel Partnership Consortium (AISI, Major Steel Corporations, Automotive OEM’s and the Dept. of

Energy)

4

Derek Hunter

• Investigate weight reduction opportunities without influencing structural integrity, manufacturability

or costs.

- Alternative designs (hydro-form, multi-piece structures, combined stampings, etc.)

- Materials (HSS, DP and laminate steels, hybrid steel-plastic, etc.), and

- Methods of manufacturing (laser welded assemblies, hydro-form tube and sheet, etc.)

• SME for Advanced Manufacturing Engineering Team focused on next-gen closure projects and

designs. Project concepts developed with multiple product, material and manufacturing companies

across industry.

May00 to Dec00 - Wagon Automotive Inc. - Wixom, MI

Advanced Manufacturing Engineering Manager / Project Manager – Technical

Wagon Automotive is a Germany-based Tier I automotive supplier specializing in the design and

manufacture of lightweight aluminum vehicle doors and body components. First Aluminum Vehicle

Closures and Body Group engineering employee hired in N. Am. Responsible for all project manufacturing

development, strategies and direction and customer liaison activities to support the first US OEM closure

program

• AME and Project Manager (Technical) for the Ford D219/258 front and rear aluminum closures.

• AME Manager role:

- Responsible for ensuring all designs and changes were feasible for manufacture

- Determine manufacturing footprint and support efforts to define production facility of Ford

Supplier Park site

- Ensure Wagon supply-base cost, timing and related financial activities were accounted for.

May96 to May00 - Brose North America and Brose Fahrzeugteile GmbH

Door System Program Team Engineer / Project Manager - Technical

Brose is a German Tier I automotive door component and door module system supplier. NA Operation

start-up engineering employee assigned to Vehicle Door Modules, Interior Components, and Mechanisms

Group. Company Ex-Pat assignment in EU for 2 years - re-assigned to the N. Am. office after completion.

Brose N. American Assignment: May98 to May00 – Brose North America - Auburn Hills, MI

• Door System Program Team Engineer / Project Manager - Technical - Responsible for the program

transfer and launch of the global CW170 (Focus) door platform for Brose. Global launch – Sequenced

12 mos. launch separation for EU and NA

• Led all N. Am. project engineering planning and implementation of the CW170 door system and

assured all global directions, functions and technical details were carried over.

• On-sight supplier support for customer engineering and launch through JOB1. (US, Mexico)

• Provided product and manufacturing support for start-up and production launch of Brose, Queretaro,

MX assembly lines.

• Door system product engineer responsible for the M205 door system development, product

engineering, and PMT activities

Brose Germany Assignment: Jan98 to May98 - Brose GmbH (Corporate HQ) - Coburg, Germany

• Door System Program Team Engineer for Ford Focus EU and NA Program.

• Customer launch and liaison engineer at Ford site through JOB1. (Germany, Spain)

• Assigned to Brose GmbH Ford Team. Responsible for product engineering development, product

validation, related APQP/PPAP activities, scheduling, manufacturing and capacity planning for

operations in Europe.

• Provided product and manufacturing engineering support for start-up and production launch of Brose

UK assembly lines.

Brose UK Assignment: Jan97 to Jan98 - Brose Ltd (UK Division) - Coventry, England

• Door System Program Team Engineer for Toyota Europe Program

• Customer engineering, liaison and launch support at Toyota UK (TMUK) facility in Derby.

• Responsible for the program life-cycle - from product engineering to manufacturing of the supplied

door system

Brose Germany Assignment: Jul96 to Jan97 - Brose GmbH (Corporate Headquarters) -

Coburg, Germany

2D7mh Page 5 of 7

• Door System Product Engineer - Transferred from Brose N. Am to Brose HQ in Germany.

• Product and Manufacturing Engineering Technical Program (Germany) – Technical education program

for product development, manufacturing and industrial engineering

PROFESSIONAL EXPERIENCE

Mar95 to May96 - ITT Automotive - Auburn Hills, MI

Senior Product Engineer / Design Leader – Chrysler Group - ABS Brake Systems Group

• Concept design, packaging and engineering of structural ABS product assemblies for all Chrysler

Program Platforms.

Mar94 to Mar95 - Chrysler Jeep/Truck Chassis and Drivetrain Division - Detroit, MI

Senior Product Engineer / Design Leader (Contract) – Drive train Group

• Concept design, packaging and engineering of coolant systems, transmission components and

linkage mechanisms

Jun93 to Mar94 – Utica Enterprises Inc. - Utica, MI

Automated Assembly Systems Engineer / Lead - Automated Manufacturing Systems Group

• Designed and engineered automated BIW component assembly welding cells for Chrysler Platforms.

May91 to Jun93 - Boeing Commercial Aircraft Group - Seattle, WA

Assembly and Manufacturing Equipment Engineering Lead / CATIA System Focal

777 Empennage Group

• Co-lead for CNC Machining Cell for the 777 vertical stabilizer to fuselage fin-root attachment

structure.

• Member of automation exploratory team tasked with determining the technical feasibility and

business case potential of automated assembly systems for high-speed manufacturing cells for wing

structures.

Apr90 to May91 Models and Tools Inc - Prototype and Assembly Tool Engineering Group

Aug86 to Mar90 Comau Productivity Systems - Robotic Assembly System Engineering Group

EDUCATION / TRAINING / SKILLS

Embry-Riddle Aeronautical University: Aeronautics / Technical Management Seattle, WA

Cogswell Polytechnic: Aerospace Manufacturing Engineering Everett, WA

Brose GmbH / Hochschule Coburg: Automotive Manufacturing Engineering Coburg,

Germany

Carl Duisberg Institute: German Cultural and Language Studies Munich,

Germany

• Hay Group Leadership Development

• Toyota Production System (TPS), Lean Manufacturing, Just-in-Time (JIT), Value Stream Mapping, Poka-

Yoke, 5S, Kanban, Kaizen, Continuous Improvement Process, Benchmarking,

• TS16949 and QS/ISO 9001

• Advanced Product Quality Planning (APQP), Production Part Approval Process (PPAP)

• Design Validation Plan & Report (DVP&R), Design and Process Failure Mode Effect Analysis (DFMEA,

PFMEA)

• ASME Y14.5M-1994 GD&T

• Microsoft O/S: Word, Excel, Project, Power Point, Outlook, Visio, Vis-Mock-up

• CATIA: V3, V4, V5R3 and Digital Mock-up

• Q-DAS Software User Training

• Ford FTDC: WERS

• Ford FTDC: I-DEAS for Engineers

• Boeing PMP Training (PMBOK 4th Edition) and Corporate PM and RIO (BORIS) Training

• Boeing Management for World Class Competitiveness

• Boeing CATIA for Tool Engineering

• Boeing Computer Aided Theodolite Measurement and Locating System

PERSONAL

6

Derek Hunter

• Citizenship Status: US and Canada citizenship; Passport Status: US Current

• Language: Technical, industry related German

• SAE Member

• FAA Registered Private Pilot,

• Member of AOPA Aircraft Owners and Pilots Association

• PADI Certified Diver - Advanced Open Water Diver

• USA Ice Hockey Coach (Level IV)

• Mechanical Design Awards

• Hobbies include: Distance Running, Ice Hockey, Scuba Diving, Skiing, Flying, Hiking, Biking, and

Travel

REFERENCES

Available upon request

2D7mh Page 7 of 7

Contact this candidate