Transformational Global Engineering Leader, Lean & Cost Optimization

SEBASTIAN A. JONES

**********@*****.*** 616-***-**** linkedin.com/in/sebastian-antonio-jones-056981235

SUMMARY

Transformational Chief Engineering Leader with 20+ years of global experience driving engineering strategy, operational excellence, and enterprise-wide cost optimization across complex automotive and industrial manufacturing organizations. Renowned for delivering measurable business impact—leading more than 700 cost-reduction initiatives and generating over $225M in verified savings through the deployment of world-class lean systems and the development of high-performing, globally distributed engineering teams across the U.S., Mexico, Europe, and China.

Expert in leading large-scale product development and manufacturing transformation programs, strengthening end-to-end supply chains, and systematically eliminating waste through disciplined application of Lean Tools and Six Sigma Black Belt Methodologies. Demonstrated ability to modernize engineering processes, institutionalize continuous improvement, and align technical execution with strategic business objectives through data-driven decision-making, cross-functional leadership, and executive-level influence—delivering sustainable competitive advantage and long-term profitability.

KEY LEADERSHIP SKILLS

International Engineering Program Leadership & Employee Management

Manager of over 50 international employees

Black Belt Six Sigma Certified

Design for Six Sigma Certified

Value Analysis / Value Engineering (VA/VE) Trained Facilitator

Statistical Process Control Trained Facilitator

Root Cause Analysis (8D, Kepner-Tregoe)

Trained Facilitator

5S, Kaizen, Continuous Improvement Trained Facilitator

Catia (Reviewer), Mathcad

Supplier Development & Optimization

Strategic Planning & Execution

Value Stream Mapping

Manufacturing Systems Integration

Change Management

Performance Metrics

Global Cost Optimization

Lean Manufacturing Strategy

Continuous Improvement (CI)

Cross-Functional Team Management

Design for Manufacturability (DFM)

EXPERIENCE

Director of Product Cost Optimization / Kostal NA – Troy Michigan

02/2025 – 11/2025

Planned and led Global Product Cost Workshops in Europe, Mexico and China.

Led cross-functional integration between engineering, manufacturing, supply chain, quality, and regulatory teams to ensure product compliance, technical alignment, and seamless execution of program deliverables.

Implemented advanced engineering strategies and technical governance frameworks to enhance system reliability, optimize component performance, and strengthen long-term product sustainability.

Partnered closely with Kostal stakeholders and global leadership to define engineering priorities, drive architecture decisions, and maintain alignment with corporate product roadmaps and market requirements.

Championed innovation initiatives by mentoring engineering leaders, enhancing technical capability within the organization, and fostering a culture of continuous improvement across global development teams

Program Manager II/JR Automation-Nashville, TN 09/2024-02/2025

Led cross-functional project teams through the full project lifecycle, managing scope, schedule, cost, quality, risks, issues, resources, and change using a structured project execution process.

Served as the primary customer point of contact, building trusted relationships by understanding customer business needs and ensuring clear, consistent communication.

Managed project financials and performance, including budgets, timelines, production, technical outcomes, and reporting through assigned project management systems.

Applied proactive decision-making and risk analysis to address project complexity, timelines, known and unknown risks, and corrective action initiatives.

Ensured compliance with quality management systems (ISO 9001:2015), safety regulations, and organizational policies to deliver safe, high-quality results.

Chief Engineering Manager, European Business Unit / YANFENG AUTOMOTIVE INTERIORS –

Fountain Inn, SC 08/2022 - 07/2024

Directed full lifecycle engineering activities for the BMW G09/LCI program, overseeing design, development, validation, and launch readiness across multi-disciplinary teams within the European business unit.

Led cross-functional integration between engineering, manufacturing, supply chain, quality, and regulatory teams to ensure product compliance, technical alignment, and seamless execution of program deliverables.

Implemented advanced engineering strategies and technical governance frameworks to enhance system reliability, optimize component performance, and strengthen long-term product sustainability.

Partnered closely with BMW stakeholders and global leadership to define engineering priorities, drive architecture decisions, and maintain alignment with corporate product roadmaps and market requirements.

Championed innovation initiatives by mentoring engineering leaders, enhancing technical capability within the organization, and fostering a culture of continuous improvement across global development teams.

Global Leader & Cost Optimization Manager / JOHNSON CONTROLS INC. / YANFENG AUTOMOTIVE INTERIORS - Holland, MI 08/2012 - 08/2022

Directed global cost-optimization initiatives across multi-regional operations, aligning financial strategies with organizational objectives to enhance overall operational efficiency.

Led cross-functional teams to identify cost-reduction opportunities, streamline supply chain performance, and strengthen vendor negotiations on a global scale.

Championed enterprise-wide process improvements by implementing data-driven methodologies, improving operational workflows, and reducing unnecessary spend.

Collaborated with executive leadership to develop long-term cost-management frameworks, ensuring financial resilience and supporting strategic growth initiatives.

Oversaw global budget governance, providing actionable insights through financial analysis, risk assessment, and continuous monitoring of cost-performance indicators.

Lead Product Engineer / Johnson Controls Inc. / Yanfeng Automotive Interiors - Holland, MI 2003 - 2012

Led cross-functional engineering teams through the full product development lifecycle, driving concept creation, technical design, testing, and successful product launch.

Translated complex technical requirements into scalable engineering solutions, ensuring product reliability, regulatory compliance, and manufacturability.

Championed data-driven decision-making by analyzing product performance, identifying root causes of failures, and implementing long-term corrective actions.

Collaborated closely with product managers, UX teams, and stakeholders to align engineering activities with market needs, business goals, and customer expectations.

Mentored junior engineers, established best-practice engineering standards, and fostered a culture of continuous improvement and technical excellence.

Director of Value Stream Management / United Plastic Group - Chicago, IL 2003

Oversaw strategic planning for capacity, resources, and technology integration to support scalable growth, higher efficiency, and stronger delivery performance.

Built and guided high-performing teams by developing talent, implementing coaching programs, and fostering a culture centered on accountability, problem-solving, and operational excellence.

Partnered with senior leadership to translate organizational goals into actionable value stream roadmaps, ensuring clear prioritization, timely execution, and measurable business impact.

Directed end-to-end value stream strategy to enhance operational flow, eliminate systemic bottlenecks, and strengthen cross-functional alignment across production, supply chain, and engineering teams.

Led enterprise-wide initiatives to improve throughput and product quality by driving Lean transformation, standardizing processes, and establishing continuous improvement frameworks.

Program Manager (Ford NVH Acoustical Parts) / Dow Automotive, Auburn - Hills, MI 2001 / 2002

Led end-to-end program execution for Ford NVH acoustical components, ensuring technical specifications, cost targets, and launch timelines were consistently met.

Coordinated cross-functional teams—including engineering, design, manufacturing, and supply chain—to drive seamless program integration across multiple vehicle platforms.

Oversaw supplier performance and readiness, resolving technical risks and production barriers to maintain uninterrupted program milestones.

Managed program financials and cost controls, developing forecasts, monitoring budgets, and supporting cost-reduction initiatives aligned with Ford's expectations.

Delivered comprehensive program reporting to leadership, highlighting status, risks, mitigation plans, and quality metrics to ensure informed decision-making throughout development phases.

Engineering & Maintenance Manager / Keystone - Ada, MI 2002 / 2001

Led cross-functional teams in executing preventive and corrective maintenance programs, reducing downtime and prolonging asset lifecycle.

Oversaw technical projects from planning through completion, coordinating resources, contractors, and engineering support to meet operational requirements.

Implemented maintenance best practices and continuous improvement initiatives, strengthening equipment integrity and supporting production efficiency.

Managed engineering documentation, compliance standards, and safety protocols while fostering a culture of technical excellence and operational accountability.

Directed daily engineering and maintenance operations, ensuring optimal performance, reliability, and safety across all facility equipment and systems.

Senior Program Manager – Automotive / Cascade Engineering - Grand Rapids, MI 1986 / 2000

Led cross-functional automotive programs through the full product lifecycle, aligning engineering, manufacturing, supply chain, and quality teams to deliver high-performance vehicle systems on schedule and within scope.

Drove strategic program planning by defining requirements, establishing governance structures, and implementing risk-mitigation frameworks that strengthened program execution and stakeholder confidence.

Collaborated closely with OEMs, suppliers, and executive leadership to define technical priorities, negotiate program deliverables, and ensure alignment with product roadmaps and regulatory standards.

Optimized program operations by introducing structured project controls, improving communication channels, and enhancing team collaboration to accelerate decision-making and reduce cycle times.

Championed continuous improvement initiatives across global teams, leveraging data-driven insights to enhance program quality, elevate customer satisfaction, and support long-term business growth.

EDUCATION AND TRAINING

Master of Science: Master of Science in Administration 2001

Central Michigan University - Grand Rapids, MI

Bachelor of Science: Bachelor of Science, Industrial Engineering 2000

Central Michigan University - Grand Rapids, MI

Certificate in Lean Manufacturing 2000

University of Michigan College of Engineering - Ann Arbor, MI

Associate Degree, Electronics Technology & Plastic 1993

Grand Rapids Community College - Grand Rapids, MI

HONORS & AFFILIATIONS

Delta Phi Alpha Honor Society

President, Diversity Council

International Business Traveler / Business Visitor Clearance

Member, Church Set-Up Team

Assistant Football Coach, Ypsilanti High School

Professional Athlete, National Football Association

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