Experienced, enthusiastic and effective technical leader with proven results in all aspects of product development and validation; manufacturing engineering; lean manufacturing; plant management with P&L responsibility and product launch within the international automotive industry. Successfully completed overseas assignments. Very experienced and highly effective problem solver with excellent conflict resolution skills.
Areas of Expertise Include:
• Fluent in German / English • TS 16949 Background
• Effective Communication Skills • Solid Automotive Background
• Patent/IP Portfolio Management
• Strategic Planning
• Proficient Computer skills (MS Office)
• Multi Product / Market Experience
• Mergers & Acquisition Experience • Manufacturing Engineering
• Hydroforming & Injection Molding
• Full P&L Responsibility • Subject Matter Expert Change Mgmt.
• Team Building & Leadership • Manufacturing Technology
• Strong new Product Innovator • Lean Manufacturing Techniques
• Hands on practical experience • Strong Analytical and Math Skills
• Development of sound strategies • Advanced Problem Solving Skills
• Direct sequence supply experience JIS
Eberspächer North America, Inc., Tuscaloosa, AL 2011 – 2016
Premium JIS manufacturer of complete automotive exhaust systems for Mercedes Benz, Volkswagen, BMW, others
Engineering Manager (Senior Staff Level – Lean)
Manage manufacturing engineering in a very lean environment. Plan and execute new product launches, reduce waste and manufacturing cost, plan tooling & equipment. Improve methods and key performance indicators. Senior staff level.
Impact: Transition from significant losses to budgeted profitability in 3 years (became#1 Plant). Implementation of lean manufacturing environment with zero PPM and 100% delivery.
Implemented tools, fixtures and methods were quality is inherent in the manufacturing process. Significantly reduced cost of quality. Plant achieved 0 PPM in August 2013 for 19 month, at 100% delivery.
Improved adaptive catalytic converter canning with subsequent integrated load verification measurement per Mercedes requirements.
Implemented APQP with high focus on early supplier involvement, supplier capability development and elimination of long term deviations. Executed simultaneous engineering approach for new projects with PD team located in Germany.
Revise plant layout and relocate equipment. Shut down one plant and moved all equipment to another plant while producing and direct sequencing parts to MBUSI and VW.
Added 50,000 sqft. building expansion to allow for vertical integration of purchased components.
Built engineering staff to meet challenging future requirements & growth.
Resolved supplier quality and purchased part fit-up issues. Eliminated all lifetime deviations.
Initiated technical training to establish key competencies in critical areas needed for independence from equipment suppliers.
Changed fixed output welding cells to smaller machine clusters to receive the benefits of labor scalable production output required to meet daily changing customer schedules in a JIS environment (true lean implementation).
Introduced new welding technologies to Eberspächer which later became global company standards.
Implement formal processes for continuous improvement, tooling maintenance, engineering hold area, LPA, audit of process supporting information.
Generated value stream maps to identify waste and implemented lean processes following modified TPS principles and Kaizen circles.
Transition from paper postings for operator instructions, safety instructions, quality alerts, etc. to electronically displayed information with online updates.
Interview, select and hire specific appropriate engineers, restructure engineering department and establish responsibility matrix.
ESAB Welding & Cutting N.A., Hanover, PA 2009 - 2011
Worldwide producer of welding consumables and equipment
Director of Engineering Consumables N.A.
Manage engineering departments in charge of consumables manufacturing such as flux & metal cored welding wire, blank solid wire, copper plated MIG wire, stick electrodes and flux for submerged arc welding. Multi plant responsibility. Company was sold to Colfax in 2011.
Impact: Implemented real-time online SPC in multiple value stream processes to improve product quality and consistency. Reduced scrap from 7.2% to 1.4%.
Initiated and successfully executed supplier development program.
Generated a modified version of the APQP process for internal use to create an organized product launch process and change management process.
Instituted the use of disciplined problem solving tools (8D, DOE, 5 Why) and trained engineering & lean staff.
Multiple plant responsibility for engineering activities. Lean implementation, 5S, and OEE improvement. 18 direct salaried reports in different locations. Senior staff level.
Large scale project management and capital budget responsibility.
ShapeCorp, Grand Haven, MI 2000 – 2009
Tier 1 producer of automotive bumpers, side impact and other crash management components, modules and systems made from steel and various molded plastics.
Director of Product Development Europe (2002-2009)
Business Unit Development European OEM (2002-2005) Frankfurt, Germany
Design and development of automotive safety products according to European & US crash safety requirements and standards. Relocation to Germany from 2002 – 2005 to lead establishment of a European engineering presence and manufacturing plant. Leadership and coordination of all sales, technical and commercial aspects (P&L resp.). Managed all requirements leading to customer proposals, design & engineering as well as customer communications. Direct customer contact with VW, Audi, BMW, Mercedes Benz, Seat, Saab, Porsche to sell automotive steel and plastic products. Familiar with IIHS & NHTSA vehicle occupant safety requirements and testing.
NetShape Inc. : Design and manufacturing of injection molded energy absorbers for front bumpers, side impact components and interior energy absorption components for head and knee impact absorbers (interior). Development of pedestrian impact products (husky presses 1200 to 3500 ton).
Impact: Obtained order for 2 million seat back cross members annually. Penetrated customer forward sourcing, purchasing and technical development groups to open doors for future business. Grew plastics business from 2 presses to 7.
Side Impact & Occupant Protection Development Manager (2000-2002) Grand Haven, MI
Focus on development of automotive side impact crash energy management systems.
Impact: Obtained production orders from GM Holden for a successfully developed and patented side impact system.
• Developed and patented cost efficient and low mass side impact systems meeting FMVSS 214 requirements.
• New product development from concept through FEA to prototype and production.
DEHA International, Inc., Livonia, MI 1996 – 2000
Engineering and prototype company specialized in hydroformed automotive components.
Managing Director / Technical Director
Engineering services and intellectual property company
Responsible for sales, P&L, engineering, hydroforming design & tooling, patents & IP, conducting training seminars and customer contacts.
Impact: Doubled sales and increased profits to double digits. Planned and built prototype facility.
• Established prominent customer base for a relatively small and new company.
• P&L responsibility.
• Negotiated profitable sale of the company and its IP in 1999.
MascoTech, Canton, MI 1994 – 1996
Automotive tier1 supplier for exhaust system components and other tubular products.
Director of Technology
Responsible to direct the implementation of new technologies, from development to launch. Management of manufacturing engineering staff, project & program management, grounds and facilities management, product engineering and customer interface. Responsible for all IP and patents, bilingual supplier management and development in US and Europe. Developed hydroformed automotive components, faucets, and military parts.
Impact: Developed new hydroformed exhaust manifold design resulting in purchase orders from Ford. Managed construction and startup of a new hydro forming manufacturing facility.
• International transfer of new hydroforming equipment from Germany. Installation and startup in new plant.
• Managed the implementation of hydroforming technology, machines, people, skills, training, launch, production.
Tenneco Automotive, Grass Lake, MI 1990 – 1994
Automotive tier 1 supplier for exhaust systems and active noise cancellation for OEM and aftermarket.
Corporate Manufacturing Systems Group
Provide technical direction to 17 Walker plants worldwide (Europe, Australia, US, Mexico, Canada), focused on key technologies within the exhaust system technology. Engine dynamometer testing for emissions control development.
Impact: Cost reduction & continuous improvement specialist. Managed the acquisition of a major European competitor. COC for 7 technology areas.
• Developed and refined powder metal welding technology applicable to automotive exhaust systems (OBD-2).
• Standardized manufacturing practices through 17 plants (11 USA) for 7 group technology areas (Best Methods)
• Participated in the acquisition of Gillet Europe. Evaluation of plants worldwide and recommendation for further action.
• Review and pre-approval of capital equipment requests.
• Responsible for acquisition preparations, strategic planning and companywide cost reduction program.
• Responsible for sale and purchase of all used capital equipment.
Manager of Engineering & Facilities – Hebron, Ohio
Responsible for management of OE engineering, manufacturing engineering, grounds and facilities management, skilled trades, tool and machine design, environmental and safety, cost estimating and industrial engineering. (Exhaust system plant).
Impact: Optimized process flow and layout. Implemented one-piece-flow. Eliminated waste and reduced scrap. Implemented lean manufacturing practices. Managed major environmental remediation project.
• Implemented “Best Methods” system through all plants worldwide to standardize best practices.
• Expanded tool room to build critical and expensive tools in house vs. purchasing.
Benteler Industries, Grand Rapids, MI 1984 – 1990
Automotive tier 1 supplier for axles, sub-frames, exhaust systems, side impact components, engine cradles and other.
Manager of Manufacturing Engineering, Tool Design & Facilities
Responsible for all manufacturing engineering, grounds and facilities management, equipment, maintenance & skill trades management. Special and custom machine design and build. Engine dynamometer testing for component durability.
Impact: Managed the development and implementation of laser technology and robotic laser cutting of tubular products to support manufacturing of a key product. 13 systems followed, subject to two US patents.
• Launch of automotive product lines.
• Created, trained and managed a technical staff to support all high tech equipment 100% in house.
• Optimized efficiency of all robotic weld cells and laser cutting operations plant wide.
Benteler AG, Paderborn, Germany
Transfer from Germany to USA in 1984
B.S. Mech. Eng. / Machine Building, Germany
Business Administration & Accounting, Germany
SEMINARS AND CERTIFICATIONS
Certified Robotic Service Engineer (ABB), Electronics Engineering Seminars, Laser Robotics (Ann Arbor MI), SME and AWS Educational Programs (Columbus Ohio), Franklin Time Management (Franklin Institute), Dale Carnegie Seminars (3), Workforce (E.E.O. Seminar), ABC (activity based costing), AQP (advance quality planning), DCP (dimensional control plan), SPC, DOE (Tag.), 8-D, Performers Club – (Chicago, IL), Program Management Seminars, TQM - Total Quality Management, MBO - Management by Objective, CIP, Cost Improvement Process, Advanced MS Excel & Project, Problem Solving, Advanced Problem solving, Conflict Management, PFMEA / DFMEA, VA / VE, Value Stream mapping, Union avoidance strategies, Lean Manufacturing, 5S, Lean Manufacturing (Alabama State)
I speak and write fluent German and English and I am authorized to work for any employer in the USA and EU.