Management Engineer

Sam Nikou, P.Eng.

416-***-**** ******@*****.***

Operations Director

Global Team Management

Over 15 years of global leadership and management experience, including

current Director of Program Management & Manufacturing position.

Employers/clients include Motorola, Daimler-Chrysler, GM, MIS Electronics,

and other leading companies. BSME degree, P.Eng. Achievements:

6-Figure and Multimillion-Dollar Cost Savings Lean Six Sigma

Implementations

Double-Digit Productivity and Efficiency Improvements QA and

Certification Goals

OVERVIEW:

. Quality-driven leader with engineering expertise and a strong strategic

and tactical background in high volume manufacturing and production

environments, including 2 decades in the Global Automotive, Mobile / Data

Communications and Consumer Electronics industry.

. Collaborative and motivational manager who can manage large,

multicultural teams, build successful relationships with team members,

vendors, customers, and partners.

. Proven record of improving manufacturing and engineering processes as

well as creating global strategies, building structured environments for

success, developing staff roles and responsibilities, and optimizing team

performance. Excellent project manager who develops and executes

successful project timelines.

CORE SKILL AREAS: Continuous Process Improvement Lean Manufacturing

Program & Project Management New Product Introduction (NPI) Six

Sigma Outsourcing Manufacturing Supply Chain Management Kaizen

& Kanban Methodologies Cross-Functional Team Leadership Total

Quality Management (TQM) Organizational Development Capital Planning

& Management Staff Training & Evaluation TS 16494, ISO 9001, 13485,

18001 and 14001 Standards Strategic Customer & Supplier Negotiations

Kepner Tregoe Management Methods Toyota Production System (TPS)

GD&T Joint Design Manufacturing (JDM)

Professional Experience

MIS ELECTRONICS, INC. - 2010-Present ($40M+ provider of Electronics

Manufacturing Services [EMS])

Director, Program Management & Manufacturing

Oversee new product development and product lifecycle activities for new

automotive, data communications and consumer electronics applications.

Train, coach and lead team of up to 40 direct-report engineers in designing

and product-manufacturing releases, ensuring fulfillment of quality,

reliability, and cost goals.

Define, develop, and execute resolutions for product issues. Facilitate

customer relations efforts between engineering, manufacturing, sales, and

marketing departments. Create strategies to reduce costs, increase

capacity, and improve program execution without compromising customer

specifications.

. Captured a $534,000 warranty savings by leading a team of engineers in

resolving a chronic field issue; additionally captured $500,000 in

supplier cost reductions through contract negotiations.

. Developed and implemented a $1.5 million localization strategy and

supply base consolidation that improved costs, productivity, and

efficiency.

. Maintained key performance indicators on $40 million in revenues by

optimizing customer relationships and integration between engineering,

manufacturing, sales and marketing on electronic control modules.

. Implemented Lean Six Sigma principles to improve operational

effectiveness as well as increasing profitability. Established a quality

and manufacturing baseline for value stream mapping, 5S process, and

VOC/product improvement studies.

. Led the organization to achieve a 60% new business win rate and $5

million in new business by creating a manufacturing quoting model that

increased the organization's market competitiveness.

. Drove development and implementation of the Automotive ISO/TS16949:2009,

with the organization achieving certification in 12/2014.

. Hired, mentored, and managed resident engineering to support customer-

awarded programs, APQP, Validation, and Launch initiatives to meet

customer's critical timelines.

MOTOROLA SOLUTIONS - 2009-2010 (Industry-leading global provider of

mobile computing solutions)

NPI Project Manager

Brought on board to drive improvements in NPI product development

processes. Developed and established best practices in PDP, engineer teams,

product development, and technical liaison activities. Provided a common

interface for internal groups and external vendors to meet needs of

manufacturing and operations.

Planned and executed project management for all supply chain activities

affecting product development projects, creating NPI guidelines for smooth

engineering-to-contract transitions. Created Statements of Work (SOWs),

Requests for Proposals (RFPs), and contract management processes.

. Achieved 50% workforce reduction in 6 months and $176,000+ in annual

cost savings by authoring and leading standardization and continuous

improvement of projects for key manufacturing operations.

. Reduced required number of parts by 30% and assembly time by 45% through

role as Design for Manufacturing (DFM) Champion, achieving cost

reduction while upholding high quality levels.

. Ensured proper qualification of new suppliers through auditing and

scorecards; ensured adoption and support for strategies through liaison

efforts with commodity teams.

FLEXTRONICS AUTOMOTIVE, INC. - 1997-2009 ($1.4B company specializing in

vehicle-based products/solutions)

Senior Manufacturing Engineer

Served as a Project Team Leader, executing and directing Tier 1 and 2

automotive electronics and electro-mechanical manufacturing for Daimler-

Chrysler and General Motors. Developed and managed manufacturing capital

projects for GM's 360 driver door/passenger modules. Launched and managed

from the product development phase (PDP) to the production part approval

process (PPAP) core production lines using the AIAG APQP process. Served as

the primary customer liaison for technical design and manufacturing issues.

. Yielded 16% OEE improvements and generated $82,000 in annual savings by

championing continuous improvements via Lean and Six Sigma methods, as

well as investigating process sequences via DMAIC.

. Prevented catastrophic failure and millions of lost dollars on recalls

by applying Pareto analysis on tracking dealer and OEM warranty failures

on various platforms, using fishbone analysis to identify root cause,

and facilitating design/process changes that improved product

reliability.

. Captured $800,000 in annual savings on Chrysler's production through

resource management, tooling changes, and reduction of set-up time and

load/unload processes.

. Defined and led technical specification standards for the "Machinery

Quality Management System" that captured evaluation and qualifications

required for components lists, tools, automation, safety, and key

process capabilities.

** Prior: Process/Quality Engineer, Collins & Aikman; Junior Mechanical

Engineer, AMCAN Manufacturing **

Education & Credentials

Bachelor's Degree in Mechanical Engineering

CARLETON UNIVERSITY, Ottawa, Ontario

Certifications/Licenses/Training

Licensed Professional Engineer of Ontario - Professional Engineers of

Ontario

Design for Six Sigma - Versatile Visuals, Inc.

Project Management - International Institute for Learning

Other Training - Reliability Engineering; ANSYS FEA; Kepner Tregoe

Management Methods; GD&T

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