Project Manager Engineer

Paul F. Brockhurst

****.**********@*****.***

**** ****** ***** **** ***** (M): 314-***-****

O Fallon, MO 63368

Career Profile

** ***** ** ***** **********, manufacturing engineering, quality and project management experience

Very effective hands on manufacturing and operations leader with strong business acumen

Highly motivated self starter with strong history of success in roles of increasing responsibility

Strategic problem-solver with successful history of cost reduction and continuous improvements

Experienced in Team Based Concept, 5S and LEAN initiatives

Project manager from start to finish for new product/process launches

Sound decision making skills

Talented in root cause analysis of equipment malfunctions and process deficiencies

Excellent communication and organizational skills

Professional Experience

Pretium Packaging, Chesterfield, Missouri

Engineering Manager 2010 to present

Corporate leadership position responsible for planning and managing capital projects to improve and grow manufacturing operations, while meeting all customer expectations, for a $156M plastic container manufacturing company consisting of eleven manufacturing plants throughout the U.S. and Canada.

• Managed a $1.3M project for the integration of a blow molding plant in Hazleton, PA into our flagship plant located in the same city. This required upgrades to the receiving plant’s chilled water, electrical and compressed high pressure air infrastructure prior to transferring and getting into operation seven transferred plastic blow molding machines. All targets met.

• Managed a $1M project to modify and move an automatic palletizing unit from Montreal, Canada to Walterboro, S.C. and a plastic blow molding machine from Hazleton, PA to Walterboro, S.C. This was done to support a large contract with a new customer. Responsibility included defining the scope of work, putting together bid packages, awarding contracts and managing contractors and internal staffing in Canada, Pennsylvania and South Carolina while keeping the customer apprised of adherence to published timeline. All targets met.

• Procured capital and managed $700,000 project for the integration of blow molding operations at a Muscatine, IA manufacturing facility into existing facilities in Seymour, IN and Manchester, PA. This included purchase and optimization of chilled water systems, compressed air systems, electrical systems, cooling tower water systems and de-install/install/transport/re-install of six plastic injection blow molding machines each in excess of 40,000 pounds. All targets met.

• Spearheaded a $1.4M project to purchase two new blow molding machines, install them in our flagship plant, and transfer two existing blow molding machines from the flagship plant to plants in Peru, IL and Anaheim, CA without impacting customer shipments. All targets met.

Each project requires the following:

• Define a scope of work based on customer and internal requirements

• Obtain budgetary quotes / use historical figures to create capital expenditure requests (CER)

• Issue RFQ’s to contractors, review contractor bids, negotiate terms and award final contracts

• Create project timelines and manage cross functional team adherence to timeline

• Manage contractors and internal personnel throughout the projects to insure budget, work scope, safety and quality requirements are met

• Develop risk mitigation plans to protect the customer and my company

• Confirm all systems meet functional requirements prior to closing project

Henniges Automotive, Formerly GDX Automotive, New Haven, Missouri

Assistant Business Unit Manager / Sr. Process Engineer / Quality Engineer 2005 to 2010

Tasked with responsibilities of Assistant Finishing SBU Manager overseeing staffing, production planning and ship schedule adherence in addition to engineering responsibilities for a $90M union-free vehicle sealing systems plant

Dual engineering role - responsible for leading process and quality initiatives for EPDM rubber and TPV injection molding finishing operations

Highly versatile leader tasked with increasing levels of responsibility

Praised for on time project deliveries and high level of customer satisfation

Team Leader for:

• 3 Salaried Supervisors

• 4 Salaried Manufacturing Engineers

• 6 Quality Engineers

• Approximately 150 hourly team members

Launch coordinator for GMT900 secondary seal manufacturing cell worth $20M in annual revenue

• Accountability for manufacturing and quality system implementation

• Responsible for specification, quotation, and supplier management of new equipment fabrication

• Launch noted as “flawless”

• Face to the customer on all manufacturing and quality related issues

Launch coordinator for VW sealing system cell transferred from a closed plant

• Drove retooling plans, rebuild plans, and equipment cleaning and painting

• Established staffing structure and devised lean manufacturing layout for transition

• Implemented total quality process necessary to meet customer’s stringent requirements with flawless execution

• Slashed labor by 50% and captured $4M profit increase over previous process owner

• Reduced official customer quality complaints by 80% and earned commendation for transfer and launch as “flawless”

• Face to the customer on all manufacturing and quality related issues

Leader of lean manufacturing initiatives creating process yield improvements, cycle time reduction and variability reduction - worth $1M savings in 2009 calendar year

Leader of continuous improvement initiatives worth $750K savings in 2009 calendar year

Involvement in establishing fiscal year productivity and scrap budgets

Monitor, communicate and push continuous improvement of all performance metrics

Encourage and motivate teams to achieve productivity, scrap, 5S and quality goals

Delphi Automotive Systems, Kettering, OH

Project Manager / Product Engineer III 2002 to 2005

Product/Project Engineer responsible for navigating design, development, validation and manufacture of strut module assemblies for a $200M union vehicle suspension systems plant

Cross-functional project team leader for a team responsible for saving GM client $10M per month through adherence to vehicle introduction schedule

Swiftly responded to vehicle vibration problem by leading team in forming solution which subsequently boosted profits for Delphi by 8%

Developed module designs in accordance with customer SOR

Leader of DFMEA, PFMEA, Process Flow and Control Plan creation

Leader of “running change” design modifications as required by customer

Initiated quoting and selection of manufacturers for supplied components

Root cause evaluation and corrective action implementation for both design and manufacturing challenges

Prototype development, validation testing and customer design review responsibility

“Face to the customer”

Product Engineer 1999 to 2002

Product and process improvement engineer for electronically controlled vehicle shock absorber systems

Resourcefully designed, developed and orchestrated roll-out of MSR electronically controlled shock absorbers for commercial trucking applications worth $20M annual sales revenue

Exercised sharp problem solving abilities to significantly reduce scrap from 8% to 1.2% and warranty claims by $1M

Design and development of prototype assemblies

Coordination of validation testing on vehicle and in lab environment to ensure customer design requirements are met

Valving Engineer 1997 to 1999

Responsible for design, development and continuous improvement of valving systems used in vehicle shock absorber and strut module assemblies

Analyzed and successfully decreased valving-related first-time manufacturing quality numbers from 60,000 to 7,000 ppm

Interpretation of customer issued damping requirements to design and implement valving systems meeting customer expectations

Quickly advanced from initial role as Warranty Engineer, 1996 to 1997

Training And Certification

Shainin Red X certification

Completed trainings in TS14969 and ISO 14002 Quality Systems

HAZMAT training

First Aid / CPR training

5s training

SPC and Lean Manufacturing training

Henniges Leadership Development training

Education

University of Dayton, Masters Business Administration, May 2005

University of Dayton, Bachelor of Science Mechanical Engineering Technology, December 1995

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