Project Management, Product Development, Quality, Manufacturing Engine

David Lohbauer

***** * ***** **. ****** Park, IL 60467 847-***-**** aczlt7@r.postjobfree.com

Global Executive

Global business leader with a diversified background in Engineering, Quality, Operations, and Project Management. Skilled in working with global brands across different industries including Weber, Motorola, and Caterpillar. Practiced in working in progressive executive roles to lead design, manufacturing, engineering, project management, and quality teams. Adept in leading multi-site, collaborative functions. Within different disciplines and industries. Able to offer companies a broad experiential base to grow their operations in partnership with global suppliers, manufacturing parties, and other essential stakeholders. Targeting Manufacturing Operations, Engineering, Quality and Project management roles that will allow for use of my diverse background in developing organizations, boosting efficiencies, improving processes, developing new products and expanding international reach.

Core Skills

Quality System Management Lean Six Sigma Manufacturing Continuous Improvement Manufacturing Engineering Capacity Planning Tooling Engineering Packaging Engineering Product Design Cross-Functional Team Leadership

Customer Service Project Management NPI Process Operations Coordination CapX Projects ROI Tooling & Packaging Design Coating process New Product Development Change Control Master Data Document Control

MS Office SAP AutoCAD SolidWorks Tooling Simulation

Proven Record of Achievement

Growth & Profitability: Designed and managed implementation of major CapX programs to eliminate capacity constraints resulting in 30% - 100% increase in production capacity. Engineered global expansion of manufacturing operations in China to support global growth and increase manufacturing footprint for 5 product lines building 7 base models.

Operational Excellence: Implemented Lean Six Sigma methodologies to improve efficiency and develop internal organizational capabilities to resolve complex problems resulting in manufacturing efficiencies exceeding 98%. Restructured and developed organizations through internal programs to fill difficult to hire skill positions. Initiated Project Management gate release New Product Development process to ensure all product deliverables are met. Re-designed 6 internal processes including change control, PPAP, ICAR, NCR, master data, and document control functions to improve process efficiencies.

Global Leadership Presence: Initiated a global quality management compliance system, global manufacturing engineering operations, and global Project Management product rollouts. Led global quality teams, suppliers, manufacturing introductions, and field implementations.

Accomplishments

Manufacturing Engineering:

Drove the design and implementation of new lean automated manufacturing facilities, including fabrication, powder coating, and assembly operations in support of new product releases. Grew & developed a mature engineering organization to support operational requirements internally including automation, tool design, packaging and Tool & Die functions. Defined capacity planning models to identify manufacturing constraints based on production forecast, and implemented multimillion dollar CapX programs to eliminate them. Continuous improvement efforts yielded significant process improvements for change control, document control, NPI, master data, NCR, and PPAP functions.

Increased production rates for Genesis and Summit lines by 100% through implementation of automation, improved ergonomics, and improvements in line flow.

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In order to support the growing internal demand for new T & D builders, we implemented an internal apprentice program in association with TMA

Increased production rate for Q products by 40% through implementation of internally designed & built assembly automation. In order to support increased volumes we proportionately increased tooling efficiency and line speed for powder coat operations.

Increased Charcoal capacity by 30% through the addition of a 3rd draw line, increasing furnace capacity, and improvements in powder coat efficiencies including robotic reinforcement developed in house.

Integrated the change control process from a manual to an automated work flow within SAP to reduce cycle time and improve accuracy.

Improved packaging concealed damage through design of products to exceed ISTA design standards.

Quality Management:

Implemented a global quality system supporting all manufacturing operations and global customer service organizations with KPI’s to drive performance. Enhanced internal global lab capabilities in US and China to support the new product development process, ISO compliance, PPAP, and ALT testing. Led global customer service organizations to identify and address critical product field metrics.

Corporate COQ reduced by 50% through reductions in global field claims, improvements in internal quality and appraisal costs.

Genesis, Spirit, Q, and Charcoal product line field failure rates below 0.5% through the analysis of field returns and implementation of internal quality systems. Measureable improvements seen in damage, missing parts, corrosion claims, and thermal events.

Manufacturing FPY for most operations exceeded 98% as a result of monthly QSR meetings. ICAR process implemented to address nonconforming internal processes.

Supplier quality for all incoming materials improved over 80% to 1000 PPM. This was a result of the implementation of SCAR process & QIP meetings with suppliers that did not meet quality targets.

Dock to Stock initiative improved 95% for purchased components that meet requirements.

PPAP on new products increase from less than 10% to 100%, and internal lab facilities capacity increased to support the workload. Developed ISO compliance between lab facilities in the US and China

Managed the Document control function for internal and external specifications.

oDaily internal audits performed to ensure controlled specifications are followed, and systems are operating within defined SPC control limits.

o As a result there have been no findings from external supplier and regulatory audits.

Development Engineering:

Managed multidiscipline design teams for new product development from concept to production release of mobile phones and linear power amplifier base station equipment.

Led the Mechanical Engineering development for the first Linear Power Amplifier program

Led cross functional Mechanical and Electrical development of the next generation Expandable Linear Power Amplifier program that reduced footprint by 30%

Led the Mechanical design effort for the first mobile handset to use a blue LED display and joystick control function

Led a cross functional Mechanical and Electrical team in conjunction with a 3rd party government contractor to provide secure communication of the base mobile platform.

Project Management:

Recipient of the 1998 CEO Quality Award for Project Management for consistently meeting project goals on schedule and on budget.

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Professional Experience

Weber Stephen Products LLC. - Palatine, IL 2002 2016

Sr. VP of Quality

Responsible for the global quality for this premium brand. This included supplier quality, manufacturing quality, engineering quality, lab facilities, field quality, document control, and product return functions.

Helped the company grow globally through implementation of consistent global quality systems.

Led the Quality organization in support of global operations and customer support.

Improved KPI goals in all categories including supplier quality, manufacturing quality, and product field performance.

VP Manufacturing Engineering

Responsible for manufacturing engineering, tool & die, stamping die, die casting, injection mold tool design, fixture design, paint and coating development, project management, engineering change control, Master Data, Packaging design, and lab facilities.

Developed the engineering organization to have the capability to design and implement lean automated manufacturing facilities to meet new product development and capacity requirements.

Motorola - Arlington Heights / Libertyville, IL 1984 2002

Engineering Manager

Directed the efforts of multi-discipline engineering teams for new product development including design, analysis, and qualification to meet all reliability, regulatory and manufacturing compliance requirements.

Products developed included Mobile handsets, and linear power amplifiers.

Quality Manager

Managed the overall quality system for 3 manufacturing facilities.

Directed the activities of a team of quality engineers and technicians in FQA, reliability engineering, quality process, black belt program, new product release process, and outsource supplier quality.

Project Manager

Directed the project management team responsible for all Linear Power Amplifier programs including the introduction of new products into manufacturing.

Acted as primary liaison between Customer, Development Engineering, and Manufacturing on a global basis, and led efforts for field implementation of base station equipment; included on site field management of engineering teams in Japan to complete installation of new systems.

Caterpillar Tractor - Aurora, IL 1980 1984

Design Engineer

Responsible for structural analysis, design, manufacturing, and field support of rollover protective structures, loader frames, and lift arm assemblies for track type tractors and large wheel loader programs.

Designed hydraulic controls, developed system simulation models, and validated through testing

Education & Credentials

University of Illinois Champaign IL, Bachelor of Science in Mechanical Engineering

Completed Caterpillar Co-op training program while completing my degree

Member of Tau Beta Pi Honor Society University of Illinois

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