Summary

Program / Project Management Lean Manufacturing Strengths Product Development Depth

Results Oriented / Hands On Product Manager, with depth of experience in Program / Project Management, New Product Development, Commercialization of New Technology, PMO Methodologies, Business Process & Financial Analysis and Lean Manufacturing Methodologies. International business experience and MBA level business skills.

Core Competencies

Complex Project / Program Management Global Product Management

WCM / Lean Manufacturing Strategies Business & Manufacturing Process Analysis

Business Case Creation / Financial Analysis PMO Process Metrics & Methodologies

Six Sigma Green Belt Design for Manufacturability Methodologies

Design for Six Sigma Methodologies Verification / Validation Testing

ERP Implementations (Oracle & IFS) Cross-functional Team Builder

MS Project; EVMS & Other Metrics Currently Pursuing PMP

Professional Experience

Performance Solutions Sep 2014 - Present

Principal Consultant

Manufacturing Business Consultant concentrating in Program / Project Management providing end to end management of scope creation, schedule & cost baseline development, identification of capital and resource requirements, and execution to manage the deliverables; Manufacturing & Business Process Modeling for process improvement and process re-engineering; Business Analytics providing product / service pricing models and operations financial models needed for identifying improvement opportunities; and Training in the areas of BPM and Lean /Six Sigma methodologies

Remy International, Inc. 2010 - Sep 2014

Hybrid Business Unit Leadership Team 2010 - Sep 2014

Marshalled the resources of a strongly matrixed Hybrid Team (70 professionals) in the Program / Project Management of Commercializing New Technology. Developed and executed to strategic objectives, managing and prioritization of resources to develop, launch and manufacture products that provide vehicle traction power, generators, ISG’s, BAS motors for OE vehicle applications; identifying risks to plan and developing plans to mitigate. Analyzed new business / project opportunities: determining resources required, capital investments needed, revenues and margins projected, providing overall returns and payback analysis among other project metrics. Presented resulting Financial Business Cases to executive C-leadership to gain budgetary authority to move forward with market opportunity objectives. Managed Product Life Cycle, from launch to end of life, in a fast paced Automotive environment, working directly w/ existing and prospective customers to understand market trends and executing strategies to maximize return

Product Line Manager, Hybrid – Light Duty & Heavy Duty Hybrid Motor Product Mgmt 2010 – Sep 2014

Leadership and direction of large cross functional product line business team. Directed multiple resource groups, collaboratively working to develop and launch a portfolio of Hybrid electric motors and inverter drive electronics for 48V, 350V & 700V Applications. Collecting VOC data; establishing requirements documents; developing product roadmaps; capitalizing and establishing operational facilities and equip. for product line readiness; Created detailed Business Cases necessary for quoting market opportunity, and financial investment returns analysis (ROI and others) to support Capital plans required

Accomplishments:

Established global product launch plan with multiple product lines sited in Mexico, China & Hungary to meet customer & market launch requirements for Hybrid electric motors and drive electronics

Managed Product Profitability - leading efforts for continuous improvement of overheads, VaVe, material & manufacturing process costs and pricing as needed

Developed product roadmaps and defined value propositions differentiating our position in the market

Directed Program Management & Product Engineering resources through stage gate processes; leading creation of requirements documents, product development, validation, PPAP approvals, supply chain sourcing & production readiness

Developed new Project Valuation Process and Tools - Provided detailed Business Case creation & financial analysis to support which group of projects in the portfolio to continue pursue based on financial return and resources required (people, time & Investment)

Developed new Quoting Process - Led cross functional efforts in the creation & analysis of complex Business Cases w/ required costed BOM’s and capital deployment estimates to assist our Light & Heavy Duty Sales teams in support of quoting opportunities

Developed and executed yearly Hybrid capital plans and managed the departmental SEA budget objectives for Annual Operating Plans

Managed capital and engineering resources to resolve cost challenges, overcome several product shortcomings through redesign and new process development, positioning Hybrid for production launch in 2013

Hamilton Sundstrand Kenosha, WI 1999-2010

Organizational Leadership Team – Part of a team that launched a Greenfield Startup enterprise. Developed and implemented new business & manufacturing processes, Implemented new ERP system (IFS), Achieved ISO9000, AS9100 and UTC ACE certifications

Successfully led the charge for implementation of Lean Manufacturing on new manufacturing product line, transforming the hybrid generator line into an efficient example of single piece flow product delivery that had 100% on time delivery for 4+ years

Sr. Program Manager – Hybrid Bus Generator & Traction Motor Development / Production 2005 - 2010

Leadership and direction of cross functional teams responsible for product design, manufacturing process, Product Verification & Validation testing, supply chain development and project data management. Responsible to propose, design, qualify, cost reduce and deploy through production, 1st & 2nd generation custom generators and traction motors for hybrid bus propulsion systems. Responsible also for complex project development & contract management, identifying / pursuing customer funding for NRE and capital investments, setting timeline and cadence for meeting milestone objectives, and providing margin management and customer relationship management. Developed and managed program, operational and capital budgets driving program to product launch. Forged Long Term Supply Agreements with customers and supply chain partners. Managed ongoing product line execution; assuring “on time” product deliveries, meeting inventory turns & quality objectives, developing long range business strategy and product improvement goals working with leadership to develop organizational strategic plan. Implemented compliance matrices to manage requirements definition, flow down and validation phases. Deployed Kanban system and Lean Manufacturing techniques to newly formed product line. Responsible for quality assessment and initiating corrective actions focused on manufacturing process improvements to ensure ongoing robust product build & delivery. Mentored & trained new program managers

Accomplishments:

Led the developments of product & process design teams to innovate the manufacture of large electrical machines providing 200 KW for hybrid vehicle powertrain requirements

1st & 2nd generation developments delivered on time / on budget

Used Process Mapping and Value Stream approaches to analyze and continuously improve business workflows and manufacturing process. Developed / Deployed Metrics Dashboards and established Best Practice Standards to sustain improvements over the long term

Provided detailed Financial Analysis to determine the most cost effective approach to manufacture motors and generators based on customer volume projections and contract delivery requirements

Led annual recertification and internal audit team efforts for AS9100 & ISO2001. Benchmarked other Hamilton Sundstrand Aerospace sites to establish Best Practice Standards for Aerospace product line

Managed corporate directed ERP changeover (Responsible for Engineering, Manufacturing & Inventory Applications / Workflows) from IFS to Peoplesoft (Oracle) system by mapping process flows to new workflows ensuring continuity of process and data

Sales & Service Manager 2008 - 2009

Business Development of new accounts with prospective customers in high margin product lines, identifying market strategies in Aerospace / Aftermarket, and Hybrid Vehicle segments.

Accomplishments:

Responsible for capture and business development of $13.7M Product line, w/ 3 year projection on new developments exceeding $40M annually

Identified & secured multiple Aerospace Aftermarket customers resulting in 20% growth of business segment

Staff Engineer / Configuration Manager / Product Design Manager 1999 - 2004

Managed engineering configurations & ERP (IFS), establishing engineering standards for all product lines. Developed motor & generator products, providing mechanical / magnetic design needed to meet customer application and regulatory requirements. Supported customers’ global production sites. Provided major customer field and product line support in Europe. Led design services team, which provided CAD support and engineering training including FMEA, Finite Element Analysis, GD&T and engineering configuration training among others.

Accomplishments:

Team deployment and implementation of new ERP system (IFS) required for the launch of new Green Field site. Responsible for business process mapping (BPM) and workflow creation for Engineering / Config & Change Management Applications, in addition to broad multi-application testing and audit. Created training materials, procedures and facilitated training of all engineering personnel on new system

Developed product test procedures to verify / validate product compliance to customer requirements. Developed / maintained compliance matrices for development programs

ERP (IFS) Engineering Superuser - managed engineering config & change workflow definitions, all personnel rights and credentials within system, in addition to training / orientation for new employees

Established & refined engineering design and change control procedures; created engineering ISO 9001 / AS9100 procedures, standard work and training materials needed to meet certification objectives

Managed large cost reduction projects to meet margin and throughput improvement objectives. Focused both on product cost reductions and re-engineering of process. Implemented large scale testing program to mitigate risks with respect to cost reductions

Pacific Scientific Rockford, IL 1991-1999

Product Line Manager 1997 – 1999

Managed & directed the activities of Generator Product Line including defining product strategy, setting and communication of goals, strategic plan and objectives. Measuring progress via Revenue, Profitability, Delivery Performance, Product Quality, and inventory turns. Restructured market channel agreements and developed initiatives for OE marketing activities and Product Development in order to meet growth objectives.

Accomplishments:

Responsible for the P&L ($2.5M)of the Generator Product Line

Introduction of Strategic Planning to this BU focusing on alternate channels and business process analysis & improvements to meet revenue re-growth objectives

Re-growth of product line revenues at 50% gross margin level

Negotiation and signing of new distributors as both sales and servicing channel for our product

Development of new distribution contracts focusing on growth incentives

Development of public eCommerce web-site for product promotion and maintenance of distribution channel

Development of offshore Supply Chain sources for cost improvement of PMDC motors / generators

Design & Manufacturing Engineering Manager 1991 – 1997

Leadership and direction of the Design and Manufacturing Engineering teams, supervising 15 engineering personnel; setting goals, measuring and appraising performance, planning and administering budgets, training and disciplining team members, planning and orchestrating multiple design & operations projects. Led engineering teams responsible for product and process development, capital equipment planning and purchase, manufacturing process modeling & improvements, cellular manufacturing techniques, targeted Oracle ERP implementation work, ISO 9000 implementation and compliance, process automation, product modifications, product quality, reliability & serviceability, CAD Documentation, PDM implementation, and product testing. Redesign and refinement of all products designs to meet CE Low voltage & EMC directives. Qualification and testing of product to meet customer application requirements (Noise, Shock & Vibration, EMC, Thermal, Life Testing, etc.)

Accomplishments:

Implemented Rapid Cycle Development program to cut development cycles by half

Introduced Project Management Metrics to drive Manufacturing & Business Process improvements

Introduced & implemented Design for Manufacturability program to reduce parts count, improving reliability

Initiated Manufacturing Process Kaizens to improve work cell effectiveness and on time deliveries

Developed Financial Analyses needed for Capital Equipment Justification and Purchase of multiple CNC’s needed to improve process, throughput & quality

ISO 9000 Implementation Team achieved certification

Development of strategic product development objectives to meet machining, manufacturability, reliability and serviceability goals

Identification and adoption of Best Practices in PMDC operations and design

Established and implemented formal cost reduction program resulting in savings of $400 - $600K annually

Education

Executive M B A 3.65 GPA Lake Forest Graduate School of Management

B S Mechanical Engineering - Thermo / Fluids Worcester Polytechnic Institute

Minor emphasis in Electrical Engineering – Electrical Machines

Pi Tau Sigma – Engineering Honor Society

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