ZAKER S. HUSSAIN

**** *. ******* **. *****, Arlington Heights, IL 60004

Cell: 847-***-**** E-mail: acxtfu@r.postjobfree.com

SENIOR MANUFACTURING AND MANAGEMENT PROFESSIONAL

Sourcing Ventures Turnaround Businesses High Growth Organizations

EXECUTIVE SUMMARY

Innovative and assertive Senior Manufacturing and Management Professional who offers a solid, verifiable career track of successfully propelling programs and initiatives that spur operational growth and profitability. Outstanding ability to identify opportunities, develop focus and provide tactical business solutions. Exceptional communicator with strong negotiation skills.

Strategic Planning & Organizational Leadership

Client, Labor & Vendor Relations

Inventory & Cost Control

Development of Maintenance Programs

Implement Lean Manufacturing

Turnaround Organizations

Outsourcing

Project Management

Process & Procedure Development

3D Solid Modeling Design

EMPLOYMENT EXPERIENCE

FORD MOTOR COMPANY, Dearborn, MI May 2011 – Present

$145B manufacturer of Automobiles

Manufacturing Engineering/Program Delivery Lead (United Auto Workers Union)

Direct the On time and cost effective delivery of large scale Engine and Transmission Programs in both United States and Mexico. Key metrics for delivery include CNC Machine process and Tooling development, Machine Cell Development, Labor optimization, Equipment Design Optimization, Cost Control, Safety and Improved Productivity.

Manage both technical and financial segments of Engine and Transmission projects with emphasis on Quality and on time delivery.

Contrive multi-million dollar solutions and derive work plans to overcome technical obstacles in the delivery of programs.

Responsible for New Program Cost Study, Procurement, Vendor and Trades Management and Capital Budget for New Programs.

Manage Projects with Budgets ranging from 1.5M to 95M with responsibility for Capital and Labor costs, and adherence to all delivery metrics while generating Cost Savings in areas of Labor, Capital Investment, Sourcing and Logistics.

Work closely with Product and Gauging groups on the development of PFMEA, CNC Process and Improved Product Design.

Work to develop capability of both Vendors and Plant personnel to establish an ownership culture to derive cost effective solutions.

Work with Labor and Plant management to optimize equipment operation and develop plant Maintenance program.

Work to optimize performance of 4-5 axis CNC mills, honing machines, In-line Gauging, Conveyor systems and leak test machines.

Utilize Global 8D problem solving techniques as well as Six Sigma DMAIC methodology to improve manufacturing process.

METALDYNE PERFORMANCE GROUP Fremont, IN (Company Sold in 2010) June 2008 – November 2010

$60M manufacturer of Automotive Oil pumps; with 150 employees

Engineering and Maintenance Dept. Manager 8 Direct Reports (United Auto Workers Union)

Manage Process Engineering, Maintenance Department and EHS (Environmental Health and Safety). Responsibilities include planning equipment rebuild, development of preventative maintenance program, Negotiations with suppliers and customers, Design and upgrading of tooling for machinery and guiding advancement of action items that address plant uptime and finances.

Improved up time over 35% by improving machinery and setting up a Computerized Maintenance Management System. Plan, Direct and Oversee the rebuild of Alfing, Mori-Seiki and Shigya CNC equipment that includes redesign of tooling.

Develop network of sourcing partners and vendors that enabled rapid procurement of key plant and machinery components and negotiate off site inventory of high ticket items with sourcing partners.

Served as a change agent to change the fire-fighting culture of plant personnel and establish a culture of responsibility and ownership in the areas of Engineering and Plant Maintenance to improve plant financials.

Develop Plexus Computerized Maintenance Management system to establish Preventative and Predictive maintenance systems.

Developed Engineering and logistical solutions to overcome issues with inventory, product quality, production improvement.

METALDYNE PERFORMANCE GROUP Niles, IL (Plant shut down Dec 2009)

$28M manufacturer of Aluminum Die Castings used in transmission components for Automotive Industry; with 230 employees

Engineering and Maintenance Dept. Manager 29 Direct Reports (Non-Union), $1.7M Annual Budget

Manager charged with controlling Engineering, Equipment Maintenance and Safety in Aluminum Die-Casting / Machining Plant. Responsibilities include Process Engineering and Equipment Engineering to achieve cost effective solutions for Facilities and Machinery and improve plant P&L. Delegate activities to Supervisors and guide advancement of action items that address process improvement and machine uptime while working closely with Product Development on FMEA.

Guide and direct repair of THT, Lester and Prince Die Cast Machines, Cooling Towers, Melting Furnaces and Shot Blast units thru use of Computerized Maintenance Management System (CMMS) and developed a Total Productive Maintenance Program.

Negotiated pricing and delivery with vendors that led to faster turnaround time and yielded cost savings greater than 50%.

Assisted with design of new Transmission valve body and Center support castings utilizing both Pro Engineer and Solid works in collaboration with Ford Motor Company and General Motors while performing feasibility analysis and Magma Flow simulations.

Direct rebuild of vertical die cast equipment to increase thru-put from 3600 units/week ($1.87M) to 9100 units/week ($4.73M).

METALDYNE PERFORMANCE GROUP, JERNBERG INDUSTRIES Chicago, IL March 2006- June 2008

$300M manufacturer of metal forgings for the automotive, agricultural industries and perform value added services; with 1200 employees

Design Engineering / Manufacturing Project Manager 2 Direct Reports, $2.5M Annual Budget

Engineer recruited to manufacture and institute design advancements to present process to enhance cycle time and decrease tooling costs. Progress machine operation and devise tooling and machinery to yield elevated machine running ratios.

Designed and managed mechanical upgrades to Sumitomo Presses that increased up time from 40% to 78% and utilized reverse engineering methods to design and construct new forging die sets and managed project to save $1M.

Standardized design directives utilizing Pro Engineer Wildfire that trimmed estimating and design time from 3 weeks with 3 personnel to 1 personnel for 1.5 weeks. Utilized De-Form software to analyze forging formation progression.

Directed the rebuild of 19 saws at 3 facilities to save over 200K per year in saw blade consumption in addition to developing both a predictive and preventative maintenance program for the saw departments.

Collaborated with machining shops to repair over 100,000 non-conforming parts resulting in savings of $585K.

(20 MONTH CONTRACT TERM) BIC CORP., Milford, CT, SILGAN PLASTICS, Woodstock IL July 2004 - March 2006

$100M manufacturer of lighters and pens; with 800 employees (Plant Downsizing due to Outsourcing-Brazil/China)

Maintenance Manager / Packaging Manager 56 Direct Reports (Union/Non-Union), $1M Annual Budget

Manager with full authority over packaging department for Bic Lighters.

Drove design initiatives that resulted in efficiency for J-Wrap packaging growing from 55% to over 85%, Thermoform packaging from 60% to 90% and tray packaging from 65% to 85%, resulting in overtime reduction by 70% ($350K annual savings.)

Architect Preventative Maintenance program for J-Wrap packaging line, Tray Packaging line, Thermoform packaging line, Plastic Injection Molding machinery and corrugated packaging equipment.

Improve machine uptime and direct production personnel in high volume plastic extrusion and tube printing environment.

AMERICAN NTN BEARING MANUFACTURING CORPORATION, Elgin, IL June 2002- August 2004

$2B manufacturer of bearings for automotive industry; with 420 employees

Mechanical Engineer / Project Manager

Engineer elected to oversee activities that included installation of Automated Assembly lines, Setup of CNC mills, lathes and Broach machines, troubleshooting of automation components, training and supervision of personnel.

Improved new assembly line setup time from 1 year to 5 months by simplifying processes and improving machine designs and positively impacted assembly line changeover time 150% by re-design of tooling using AutoCAD and Solid works.

Teamed with vendors in Japan and China to Design Bearing Assembly equipment in addition to establishing timetables for Construction, Startup, Commissioning and Hand-over of equipment to facility.

MITSUBISHI CORPORATION MACHINERY SYSTEMS, INC., Wooddale, IL December 1996- March 2002

$120M importer of machinery for sales and service in US, specializing in wire EDM, sinker EDM, and laser cutting machines; with 300 employees

Research and Development Engineer / Sales Engineer

Command investigation and progression of Die Sinker EDM technology. Collaborate with territory dealers to create sales tactics and exhibit imported machine tools to potential customers at trade shows.

Amplify sales of CNC Die Sinker EDM machines by employing sales strategies centering on machine strengths. These initiatives were instrumental to sales propelling from $7.75M in 1998 to over $17.5M in 2000.

Demonstrate Machine Tools at Trade Shows to capture sales leads for both new and used equipment.

Formulate testing standards and procedures for machine tuning to calibrate equipment during installation, in addition to pioneering the development of machine technology for Graphite electrode and Copper Tungsten / Carbide technology.

Develop Graphite to Steel Sinker EDM technology.

EDUCATION, RECOGNITION AND PROFESSIONAL DEVELOPMENT

Bachelor of Science Mechanical Engineering, University of Illinois, Chicago, IL May 1995

Ford Technical Maturity Model Recognition Award October 2014

Plant Turnaround and Cost Savings Achievement Award (Metaldyne Performance Group) June 2010

EDM Graphite to Steel Technology Development Award (Mitsubishi) December 1996

Contact this candidate