Tooling Engineer, Program Management

R E S U M E

Kurt Patrick Lewis, Sr.

**** ****** **.

Dryden, Michigan 48428

Home 810-***-****

Home email: ******@*****.***

OBJECTIVE:

Seeking a position that I may use my 40 years of experience, in Tooling,

Manufacturing & Quoting to add to a company's ability to grow and compete

in the Automotive Metal Stamping Industry.

SUMMARY:

Sr. Tooling Engineer at the Corporate Office, Tooling Manager/Plant

Engineer with Gestamp Automotive Lapeer Plant, I control all Manufacturing

and Tooling Programs (Quote, Design & Build to Launch) well as maintain the

current manufacturing process & tooling at the Lapeer Facility. Sr.

Program Manager/Tooling Engineer Lapeer Metal Stamping, I control the major

stamping programs from "Cradle to Grave" (Quote, Design, and Budget &

Implementation through PPAP). As Division Engineering Manager for Collins

& Aikman Plastics Division, I was responsible for the Tooling, Industrial,

and Manufacturing & Facility Engineering in eight (8) plants. This

included Cost Reduction through Tooling or Process Improvement, Capital

Budget, establish a separate Standard Cost for each facility, Plant Layouts

for Synchronous Manufacturing & Quoting Major Programs, Quoting and

Building New Facilities & closing old facilities.

With Douglas & Lomason Company I worked with eleven (11) plants in Metal

Stamping, Roll forming, Foaming, Plastic Injection Molding, Bi-laminate

Molding, JIT Seat Assembly Operations and Tool & Die. My tooling

experience is strong in Progressive, Deep Draw, Transfer, Rollforming &

Compound Dies. 15 years experience in Auto/Cad Design, Dies, Fixtures &

Special Equipment. CNC Machining Experience with Wire EDM, Turning

Centers, Milling Centers & PLC Programming.

Along with Major Equipment Acquisitions I also maintained a Capacity Study

for Major Equipment in all the facilities. I had established Standard Cost

for each plant because of different Fix&Var Burden & Direct Labor Rates.

I handled the Capital budgets in much the same way looking at what machines

needed replacement through there own efficiency using a CPK in the presses

performance. I am an advocate of "Lean, Synchronous & J.I.T

Manufacturing".

Computer Skills: All Spreadsheets, Word Processors, Timeline, Microsoft

Project & Auto/Cad 2010, etc.

WORK EXPERIENCE

Feb 2002 to Present Gestamp North America, Inc

Troy Center Dr, Troy, Michigan

Tooling Manager & Plant Engineer @ Lapeer Plant and Corporate

Sr.Tooling Engineer:

Responsible for Current Mfg Eng & Tooling, Quoting New Programs, New

Tooling, Design Approval & Plant Layout. Types of Tooling: Deep Draw,

Progressive, Line Dies as well as Mig & Resistance Welding.

I share time between the Corporate Office & the Lapeer Plant with following

major programs and quoting new programs and processes.

Accomplishments:

1. Launched 284 Jobs for the New 164 & 251 Mercedes Programs. Tooling

from 100 Ton to 1000 Ton requirements. Progressive Dies & Transfer

Dies. Traveled all over the world to do Tool buy-offs to ensure

the Part Quality and that the Tooling was built to Quoted

Standards.

2. Worked with the Corporate Office quoting the New DCX JC Program for

Mexico.

3. Worked with the Corporate Office quoting the New Nissan ZW & UL

Programs.

4. Launched the Nissan ZW & LU Programs, 18 Tools & 12 Welding Assy

Operations.

5. Quoted & Launched the GM265 Program, 74 Tools & 16 Welding

Operations.

6. Quoted & Launched the GMX-380 Program, 23 Tools, & 8 Welding

Operations.

Aug 2000 to Oct 2001 Lapeer Metal Stamping

930 S. Saginaw St., Lapeer, Michigan

Lapeer Metal Stamping has four plants in three different cities: Lapeer, Mt

Clemens and Dearborn. LMS is a Heavy Metal Stampings & Welded Assemblies

Company that services Ford, General Motors & DaimlerChrysler.

Sr. Program Manager: New Program Start-ups and Major Engineering

Changes.

Quoting, Budgets and worked directly with the Customers Product Designers

and Program Engineers. Responsibilities included Equipment & Die design

approval and buyoff.

Types of Tooling: Deep Draw, Progressive & Line Dies as well as Resistance

& Mig Welding.

Accomplishments:

1. Relocation of the complete J/F Car Seat Frame for the Lear

Corporation, Stamping & Assembly Equipment, from the GM Parma Plant

in Ohio, to LMS Plants in Dearborn & Lapeer.

2. Worked with the Ford Product Designers to reduce the time from

design to build on new stamping programs.

3. Worked on programs with Ford, General Motors, TI Automotive, VITEC

and Lear as well as the Account Manager for DaimlerChrysler, at the

same time.

4. Quoted & Launched the Ford Panther Program,

July 1997 to May 2000 COLLINS & AIKMAN, Inc.

201 W. Big Beaver, Troy, Michigan

DIVISION OFFICE: Division Engineering Manager

Duties: Manufacturing & Facility Improvements, Capital Equipment

Acquisitions, Industrial Engineering, Capital Budgets & Cost Improvement

Programs for Eight Manufacturing Plants. New facility designs and major

program quotes. Oversee all programs for Capital Equipment Installations &

Facility Improvements.

Accomplishments:

1. Cost Reductions through process improvements and purchase price

reductions, for eight plastic plants - 11 million dollars each

year.

2. Establish a load capacity study, bases on sales, for all major

manufacturing equipment. (Four years, Eight plants)

3. Maintain & forecast capital budgets. (Four years, Eight plants)

4. Facility expansions & improvements to launch new programs.

5. Plant layouts & industrial engineering for new programs, all

plants.

6. Close the Homer Plant and move all the processes to the existing

facilities.

7. Quote new programs for future business. (Process & Facility)

8. Last program launched, GMX-270 Door Panels, Instrument Panel &

Console at the Manchester Facility. This was a 16.9 million dollar

capital budget and was on time and under budget.

July 1988 to July 1997 DOUGLAS & LOMASON COMPANY, Farmington Hills,

Michigan

Manufacturing Services Manager -Eleven Facilities & Industrial

Engineering

Corporate Office Sr. Industrial Engineer

LaGrange Plant Plant Engineer

LaGrange Plant Tool & Die Manager

Carrollton Plant Production Manager

Trojan Tool Division Division Manager

Production Engineering Div.- Tool Engineer: AUTO/CAD

DOUGLAS & LOMASON COMPANY

Corporate Office: Manufacturing Services Manager - Facilities & Industrial

Engineering

Duties: Control of Corporate Capital Budget All Equipment Acquisitions

Plan, Design & Construct New Plants, Manage Start-up Team & Close Old

Plants and Sell Assets. Control the T.P.M. & O.P.S. Team. Cost Studies,

Designs & Timing on Future Facilities. Member of the International

Business Unit, Designing Seat Complete Assemble Plants. Standardize and

maintain engineering standards for all manufacturing facilities.

Responsible to oversee all new final assembly quotes for all products.

Troubleshoot existing production problems at the manufacturing plants.

Accomplishments:

1. Exceeded cost reduction goals for the company each year. Four

years Capital Budget forecasting and maintained budgets for 11

plants.

2. Plant layouts and capital acquisitions for synchronous and lean

manufacturing.

3. New Plant Start-up for Seat Complete Assembly in New Castle,

Delaware. Greenfield Operation with automated assembly, inventory

& shipping systems.

4. Closed four plants and moved operations to new profit centers.

LaGrange Plant: Plant Engineer, Tooling & Die Manager

Duties: Industrial & Facility Engineering, Plant Layout, Standard Cost,

Environmental & Safety. Troubleshoot the 5 Roll-forming operations &

Control all Press Tooling and personnel to maintain production.

Accomplishments:

1. Set the plant up in a total synchronous manufacturing production

flow.

2. Set standards for all manufacturing processes.

3. Set production control computer system in place to track piece

price cost and manufacturing standards & efficiency.

Carrollton Plant: Production Manager

Duties: Manage production floor with 150 employees. Metal stamping,

welding special pneumatic and hydraulic staking machines.

Accomplishments:

1. 150 employee metal stamping facility with 15 Rollmills for

automotive trim. Raised the plant efficiency to highest level in

plant 30 year history.

2. Introduced Plastic Injection & Extrusion into the production

process.

3. Involved Tooling & Maintenance Departments into the production

process.

Trojan Tool Division: Division Manager

Duties: Managed Tooling Division, which built Tooling for eight plants all

around the country. Complete with AUTO/CAD design and Wire EDM.

AUTO/CAD Design for Tool & Die requirements in the Automobile Industry.

Major cost savings due to redesign of old tooling for better material

utilization.

Accomplishments:

1. Guided a 40 man Tool & Die building Division that had lost money

for 15 years to a profit center in only one year.

2. Integrated Computer Die Design with EDM & automated machining to

build Dies, Fixtures and Special Equipment.

3. Major cost savings due to redesign of old tools for better material

utilization.

July 1987 to July 1988 BOSTROM SEATING, INC.

Vigo Road, Piedmont, Alabama 205-***-****

Position: Tooling Manager/Engineer, Mfg Engineer & Production Manager.

Duties: Tooling responsibilities included Estimating, Prototype, Designing,

Working with Vendors, Troubleshooting, Purchasing Tooling, Supervising

Toolroom Employees and Purchasing all necessary Tools and Equipment to

maintain a quality P.M. Program for all Tooling. Manufacturing Engineering

responsibilities included Purchasing all necessary Equipment used in the

Metal Assembly, Final Assembly, Welding and Press Departments.

Troubleshooting Manufacturing Processes to maximize work force for Product

Flow.

Oct. 1984 to Dec. 1986 DIVERSIFIED PRODUCTS

P.O. Box 100, Opelika, Alabama 205-***-****

Position: Tooling Engineer & Toolroom Manager

Duties: Supervising Three Toolrooms: Main Stamping Plant; Tube Mill Plant;

Racket Plant. Responsibilities included Purchasing all Equipment,

Machines, Tools and Dies to maintain high Production Schedules. Training

All Toolroom Personnel in the Art of Tool & Die. Plan and execute Fiscal

and Capital Equipment Budgets. Working with R & D Dept. to ensure product

development was feasibly for production. Designing all Tooling built In-

house and having Design

Approval on all Tooling built by Outside Sources.

Apr. 1982 to Oct. 1984 DYNEER CORPORATION: Spun Steel Division

518 Kraft Ave., Dothan, Alabama 205-***-****

Position: Process Engineer, Tooling Specialist & Designer.

Duties: Estimating, Designing, New Product Design, Special Tooling for New

Manufacturing Processes and Quality Control Engineer.

Nov. 1977 to Apr. 1982 TOOL PRODUCERS

400 N. Rocky River Dr., Berea, Ohio (216) 243-

4300

Position: Tool & Die Maker, Die Designer

Duties: Designing and Building Medium to Large Automotive Dies. (Deep Draw,

Compound Blank, Progressive and Transfer Type Dies.)

Sep. 1972 to Nov. 1977 S & Z TOOL & DIE, INC.

3180 Berea Road, Cleveland, Ohio 216-***-****

Position: Tool & Die Maker, Minor Design Work

Duties: Four (4) Year Tool & Die Apprenticeship and 1 Year Die Design.

Building and Repairing Die for Major Production in

Automotive Industry. All Metal Stamping Type Tooling.

EDUCATIONAL EXPERIENCE:

Max Hayes Tech School (Journeyman)

4 years Tool & Die Degree (Building & Concepts)

Lorain Community College

Designing, Mechanical, Industrial Engineering

Carroll Tech. AUTO/CAD Design, 15 years exp.

Dorian Shanin D.O.E.

Taguchi D.O.E.

Statistical Process Control

32 hr course, Dyneer Corporation

Alabama Industrial Development Training

Management Training

Graduate of West High School

Cleveland, Ohio

U.S. Marine Corps

Aviation Operations, Sgt.

References:

Rick Sneider: Dott Industries, Lapeer, MI

Pete Martz, Sr.: 810-***-**** President, Lapeer Metal Stamping

Joseph Weibricki: 810-***-**** Vice President Sales/Marketing, Lapeer

Metal Stamping

Thomas Elliott, 810-***-**** Sales Manager, Lapeer Metal Stamping

Roger Morelli: 734-***-**** Sr. Vice President, Douglas & Lomason

Dan Smith 734-***-**** Vice President Finance, Douglas & Lomason

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