Program Manager with 20 + year Automotive Experience.

JAVED AHMED

**** ******* ***, *****: 248-***-****, 248-***-****

Troy, MI 48085 E-mail: *************@***.***

EXPERIENCED IN THE FOLLOWING AREAS

•

•Product Engineering •Production Tooling/Prototype •International Business •APQP, PPAP, PDM

•Product Design/Development •Simultaneous Engineering •Change Management •GD&T, DVP &R

•Process Engineering •Six-Sigma Application •Project Strategy Planning •Cost Reduction

•Engineering Support •Problem Solving

Program/Project Management

Large Complex Welded •Trouble Shooting Team Building/Leadership

•Customer Service

Assemblies •QS/ISO 9000, QOS/TS16949

•Team Building/Goal Setting

Design for Six Sigma •TQM, VA/VE, PAP

•Business Development

Professional Experience Summary: Highly educated, well rounded, motivated Technical Leader, having reputation for

technical excellence, analytical thinking and innovative problem solving. Also known for pain staking attention to details and

consistently delivering the highest quality of Products and Services on time & within budget. Over 20 years Leadership in Engineering

and Program management in diversified Automotive Products such as Chassis, Transmission, BIW, Suspension, Door Systems etc.

ACCOMPLISHMENTS

Product Engineering: Developed JK Instrument Panel to meet Chrysler Space and Weight requirement, as well as met target cost.

Developed one piece hydro-formed Cross Member with HSLA steel to fit in customer specified new Mercedes Engine, which was larger

and heavier. Result: One-piece component development enabled us to reduce weight 3.1 pounds and achieve a cost savings of $2.9

million. Also worked on 50 millions programs with 12 Million dollars of Tooling. The Epsilon Cradle Program was given with the

challenge to reduce Wt. (Fuel Efficiency) and cost, improve durability requirements and tight timing. The Program savings are 1.5

millions. It is developed for launching three different Vehicles in US and Canada.

Program Management: Tripled Sebring program size by building customer confidence, launched program successfully on time and

under budget. Resolved the most challenging obstacle of Chrysler approval for Self Certification of Mexico Plant It was new Plant and

has no history and capability to meet Chrysler Launch Requirements. Organized team to meet Chrysler production, technical and

program management requirements. Result: Achieved cost savings of $7 millions, production lead-time reduced 35% and opened

production capacity 20%. Launched on time $50 millions programs, resulted GM willingness to offer more business (BIW and

Chassis).

Product Design & Development: Designed and Developed GM EPSILON Chassis Program. The Low Mass Cradle Design helped us

to win Business against Magna and other Suppliers. We are fully Design Responsible and successful completed “Design to Launch”

responsibility. Also, Salvaged troubled Chrysler JS Program having durability, reliability and quality issues Chassis Cradles for 3

Vehicles, including Fiat in Mexico. Executed aggressive multi-disciplined by systematic plan to meet project objectives by improving

product design (DFM). Result: Reduced launch time 35%, reduced project cost 40% (systematic and disciplined approach) and awarded

$129 million in new business. EPSILON II, Low Mass unique Design helped us also to win the Business.

Customer Service: Built outstanding business and personal relationship with Honda, Daikin, Ford, GM, FiatChrysler Automobile

(FCA) Management and Engineering to resolve a number of complex program related issues such as quality, durability, reliability, and

testing. Result: Grew business progressively with Honda from 7% to 45% over 3 years. Presently, I am working with Sales on New

Business with GM, Mitsubishi, Ford and FiatChrysler(FCA).

Business Development: Provided committed and consistent engineering support (5 years) at Tech Center and Mexican manufacturing

plants for Chrysler JX 27, JA, PT Cruiser Programs. Resolved production issues, defused timing crises, and launched program on time.

Result: Chrysler awarded the new business $129 millions without quoting the program. Cost justification was done after awarding.

Cost Saving: Applied VA/VE techniques to increase product function and reduce cost. Revised Twist Axle design to improve

performance, reduced total components and product cost. Result: Saved $ 3.5 million and also replaced 5 components with added

product function and value.

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EXPERIENCE

Sodecia, North America/AZ Automotive Corporation, Center Line, MI 2003 – present

Engineering Program Manager: Managed several multimillions of dollars programs from “Concept to Launch” for Mitsubishi, Ford,

GM and Chrysler Corporation. Responsibilities included for product design/development, business development & planning, financial

planning, prototype, production tooling, program management, cost reduction, and programs launch on time below budget. I am also

Account Manager for Mitsubishi Corporation and working to earn new business. Launched Epsilon II, 2013 Chassis Program.

Profit Margin increased from 11.5% to 29.7 % and Cost Savings is 2- 5 millions dollars, per year.

The major Programs launched are Mitsubishi, PS41 and PSU, Ford F150, 250, 350 and U264, Chrysler, JS, JK. PMMK, JS/RT/Fiat,

Instrument Panel Assembly (Stampings and components) etc. Ford 54 Assemblies were PPAPed on time, within Budget in one year.

Last Year, I launched EPSILON II Program for 2013/ 2014 for US and Canada. I lead the Team to install Robotic Weld Lines with Vision

System by Septron for Chassis Program. Also I worked on Automated Repair Station by using Machine Vision Technology.

Chrysler JS/RT/Fiat Cross Member Programs were “Cradle to Grave” responsibility. The Programs were successfully launched in US,

Canada and Mexico. I got the opportunity to use Simultaneous Engineering, Reverse Engineering, DVP &R and CAE Application on

Ford Programs. I lead Cost Reduction Teams at Sodecia more than 10 years and an active member/ Leader of Problem Solving Teams.

Sigma Six Training was also completed during this period. I headed GP 12 Teams from 24 – 48 QC Inspectors in 3 locations

(Sodecia, MI, Brighten, MI, Fairfax, Kansas). One Program Manager, 3-5 CAD Technician/Engineers worked under my responsibility.

Also managed a Big Team (45 people) of Welded Assembly Lines and Repairs (Operators, Welders, Weld Techs, Inspectors, Quality

Tech/Engineers). I successfully ran three shifts for GM Cradle and PPAPed to GM before PPAP Due Date.

I am also Account Manager for Mitsubishi for 8 years. I handle all the Commercial Issues and new Business deals with Mitsubishi.

I am closely working with our Sales Team to win new Business from Ford, GM and FCA.

Launched successfully two unique Programs (Gamma & Delta) at GM Lake Orion, MI, by building two Assembly Plants inside of Lake

Orion Plant. The Programs included “Large Welded Assemblies”, such as Floors, Structural Panels and Stampings. The key to success

was Self Directed, Well Organized, Highly Disciplined (being on Customer Floor), Highly Motivated, Resulted Oriented but People

Friendly Team Leader (GM Union Plant) with determined Team Success and Focused on Customer.

Arvin Meritor, Troy, MI 2002 - 2002

Team Leader/Engineering Manager: Managed five multi-million dollar Ford Truck Programs (F-150 Truck Series). Lead team of 32

(15Engineers & Designers and 17 Test Engineers/Technicians) as well as lead Launch Team for Ford Programs (Door Systems).

Responsibilities included Product Development, Quality Assurance, Product Testing, DVP&R and Cost Reduction (VA/VE). We

achieved Cost Savings of $2 Millions in 4 months (VA/VE Workshops). The major products were Window Regulators, Door System,

Structural Panels, Door Mechanisms (Locks, Latches, and Hinges), Stampings and Plastic Components for Ford and Chrysler.

Magna International/Cosma International, Troy, MI 1993 - 2001

Program Manager/Engineering Manager: Managed several multimillion dollar programs for Chrysler, Ford, GM, Toyota and VW

from “Concept to Launch” for 9 years. The Product included Large Welded Assemblies, Large and Medium Stampings, Door Panels

& Reinforcements, Mechanisms (Hinges, Latches, Locks), Seat Stampings, Roll Formed Rails, Suspension Systems for PT Cruiser,

Instrument Panel, Cross Members, Bumpers, Laser tailored Blank Bumpers(VW) and Floors etc. I ran Major Chrysler Programs, JS 27,

PT Cruiser, JA Right Hand Drive (USA & Mexico), Ford F 150/250/350, Utility Vehicles and GM JA Program in Mexico.

I was responsible for overall success of Programs, including interfacing internal and external disciplines such as Engineering, Finance,

Quality, Manufacturing, Sales, Purchasing and suppliers in both written and verbal methodologies. We received Customer Service

Awards from GM and Chrysler.

Responsibility was also to manage talented team of 14 Engineers and Designer in the areas of product development, prototype,

production tooling, program launch, business development, planning and QS/ISO 9000 approval and implementation.

Also Managed three Program Managers (Chrysler, Ford and GM), in USA, Canada and Mexico).

Increased overall profitability by 15%. Program Cost Savings $ 3Million to 7Million, per year in PT Cruiser Program. Played an

active role in QS and IS 9000 System implementation and got Chrysler, “Self Certification” from Chrysler for our new Mexico Plant.

L & W Engineering Company, Belleville, MI 1989 -1993

Project Manager/Senior Engineer: Responsibilities included managing multi-million dollar Honda and Daiken (Chassis, Body, and

Transmission) Programs from the “cradle to the grave”. The programs losses were turned into profits by improving product design and

process improvements in the Production Plants. Took lead in Implementing ISO/QS 9000 standards. The Transmission Business

expanded to Japan. The Die Tooling built in Japan was also a new experience to manage from USA. Building successfully Business

Relations was unforgettable experience while going through poor performance (95 % product failure rate). in the beginning of the

complex Programs where Materials, Processes, Tooling and Quality areas needed Strong Manufacturing Back Ground, Management

Skills to bring Customers on Board and provide Manufacturing Plants Leadership to understand Customer Requirements and Product

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Knowledge. The Change Management Skills and Problem Solving Skills helped me to overcome the Programs problems quickly and put

the Programs back on track to meet customer Program Timing. Also I was responsible for one Junior Project Manager for Ford.

Wah Manufacturing Industries, Wah, Pak. 1982 – 1984

Manufacturing Engineering Manager: After six Months Managerial training, given the responsibility was the supervision of 12

Engineers and multiple manufacturing engineering activities for large Manufacturing Unit in the one of the biggest company. Profits

increase by 27% and efficiency improved 11%.

It was unique experience to work on different products simultaneously. It was a great learning and a useful experience in Manufacturing.

The manufacturing was mixed with old and advanced manufacturing Technology for Stampings, Deep Draw Shells,

complex welding, Special Heat treatment Process Applications for Engine, Transmission and various components/ Products, Machining

Centers, including CNC Machining, Roll Forming and Low and Fully Automated Machining Production Lines.

EDUCATION

M.S. Mechanical Engineering (Major – Manufacturing), University of Detroit Mercy (UDM), Detroit, Michigan

B.S. Mechanical Engineering (Major -- Manufacturing), University of Engineering and Technology, LHR, PAK.

M.S. Engineering Management, Graduate Course Work, Southern Methodist University, (SMU) Texas

Areas of Study: Finance Planning, Managerial Accounting, Organization and Human Behavior, Operation Research,

Statistics, Engineering Economics, Engineering Management etc.

Continuous Education Courses: VA/VE, GD&T, SPC, FEA, FEMA, DFMA, PFEMA, APQP, QOS,QS9000, ISO9000, TS16949,

PPAP, PAP, WERS, PDM and CRID, Zero Defect, Quality, Six Sigma Methodology, Six Sigma Challenges and Application, etc.

Honors/Awards: Two Gold Medals, Three Outstanding Engineer Awards (SME, ASME), Certified Manufacturing Engineer (CMfgE),

Life Membership in SME (Reward for Continuous Education). Special Bonus awarded for outstanding performance from

Year 1993 to present, including 2008, 2012, 2013, 2014

SYSTEMS EXPERIENCE

Computer packages: MS office Suite/Office 2007/2010, 2011, Lotus Notes, MS Project, etc.

Platforms: UNIX, NT, OS/2, DOS and LINUS, Windows 98, Windows XP, 2007 and 2010.

CAD packages: Catia, PDGS, Unigraphics (UG), CGS, IDEAS, Auto CAD, Pro-Engineering etc.

PROFESSIONAL DEVELOPMENT

Completed 1650 credits in Technical and Managerial area with Professional Societies/ Institutes/Industries such

as Ford, GM and Chrysler in last 12 years. In 2014, completed 160 hours Training with FiatChrysler Automobile

(FCA) at Auburn Hills, Education Center; areas FCA, PFMEA, Control Plan, LPA, CDR,PDR,FCA Costing System.

PUBLICATIONS

Subjects included: CAD/CAM, Productivity, Quality Assurance, Management and TQM

PROFESSIONAL MEMBERSHIPS

Executive Member: Society of International Who’s Who of Professionals

Technical Member: SME Product Design and Automation Committee

Senior Member: Society of Manufacturing Engineers (SME)

Member: American Society of Mechanical Engineers (ASME)

Ex-Chairman: Society of Manufacturing Engineers (SME)

Member: Society of Automotive Engineers (SAE)

Work Authorization Status: US Citizen

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