Engineering Product Development

Kenneth J. Spear

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

**** ******* ***** **

Grand Rapids, MI 49546

616-***-**** (Home)

918-***-**** (Cell)

Summary: Skilled engineering and new product design and development executive with extensive expertise and experience in leading and directing engineering and new product development teams to design, develop, coordinate, and implement new products, on time and on budget, resulting in significant corporate growth in sales and earnings. Proven record of transforming marginally performing engineering groups into high performing development teams through the application of effective engineering and product development processes and accountability for results while controlling costs and driving innovation.

Specialties and Areas of Expertise

Extensive knowledge, expertise and experience with a wide variety of consumer, outdoor power equipment, automotive, building & construction, and commercial products

Ability to effectively build, manage, and direct cross-functional new product development teams

Strong strategic planning, project management, technical, and problem solving skills

Experience with Asian suppliers and managing Asian technical resources

Customer and end user driven new product innovation and creativity with emphasis on voice of the customer

Injection & blow molding

Product safety, product liability, and patents

Value analysis, value engineering, cost reductions

Lean design and lean manufacturing, DFM, DFA, Stage Gate NPD processes

Industry and government standards and certifications

PROFESSIONAL EXPERIENCE

Knape & Vogt, Grand Rapids, MI – Privately held by Wind Point Partners - $150mm manufacturer of consumer products including drawer slides, storage and organization products, and ergonomic office accessories

Sr. Director of Engineering (February, 2008 to January, 2011)

Reported to Vice President Marketing and New Product Development. Managed and directed Engineering efforts for new product design and development for drawer slides, home and office storage and organization products, and ergonomic office product accessories. Led product development group of 25 engineering directors/managers, engineers, CAD operators, and technicians. Responsible for new product capital budget and Engineering expense budget. Responsible for all patent activities, product standards, and global certifications. Member Executive Staff and Management Team.

Accomplishments (Knape & Vogt)

Organized New Product Development efforts into strong and effective cross-functional Product Focused Project Management Teams (8), focused on formal project management and product development techniques to consistently implement new products on time and on budget

Successfully launched several new products with incremental net sales annually in excess of $10 million

Introduced new products that more than doubled automotive sales during severe downturn in automotive industry

Refined and tailored Stage Gate process and implemented its use as an effective tool to manage NPD projects

Aggressively introduced new products growing market share during economic downturn with significantly less resources

Implemented product and process annual cost savings in excess of $1.1 million annually

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PROFESSIONAL EXPERIENCE Continued

Bush Hog LLC, Selma, AL – Division Crown Consolidated Industries (CCI) - $200mm manufacturer of agricultural cutters, landscape equipment, mowers, utility vehicles, building and construction equipment, and zero turn mowers

Vice President of Engineering (May, 2005 to December, 2007)

Reported to President & CEO Bush Hog LLC. Managed and directed Engineering efforts for new product design and development for rotary cutters, utility vehicles, zero turn radius riding lawn mowers, construction equipment including loaders and backhoes, finishing mowers, landscape equipment, and graphics. Led product development group of 56 engineering managers, engineers, designers, CAD operators, model makes, and technicians. Responsible for new product capital budget and Engineering expense budget. Responsible for all product standards and global certifications. Responsible for all patent activities, product liability, and product safety.

Accomplishments (Bush Hog LLC)

Re-built and organized Engineering efforts focused on formal project management and product development techniques to consistently implement new products on time and on budget. Effectively implemented Stage Gate NPD process.

Successfully launched 3 new platforms of rotary cutters increasing market share by 10 points to over 40% at the expense of competitors

Successfully launched 3 new platforms of zero turn mowers tripling market share in less than 1 year

Spearheaded efforts to out source utility vehicle component manufacturing resulting in $1,000 direct cost savings per vehicle

Successfully launched 6 new platforms for mid-mount tractor front loaders resulting in manufacturing ability to build to order loaders in 5 days or less resulting in $5 million inventory reduction and $1.5 million direct product cost savings annually

Dixon Industries, Coffeyville, KS – Division Blount Industries (BLT) - $40mm manufacturer of zero turn mowers and equipment

Vice President of Engineering (March, 2001 – May, 2005)

Reported to President & CEO Dixon Industries, Member Operating Committee. Managed and directed Engineering efforts for new product design and development for zero turn radius riding lawn mowers and equipment. Led group of 23 engineering managers, engineers, CAD operators, and technicians. Responsible for new product capital budget and Engineering expense budget. Responsible for global product procurement focused on product from China. Responsible for all product standards and global certifications. Responsible for all patent activities, product liability, and product safety.

Accomplishments (Dixon Industries)

Re-built and organized Engineering Team focused on lean design and manufacturing

Grew business by over 40% with attractive new and improved products launched over the period

New products introduced in 2002 – 2004 accounted for virtually 100% of sales in 2005

Successfully outsourced several components in China resulting in $750k annual cost savings

Assumed integral leadership role for marketing product management completely revamping both consumer and commercial product lines solidifying market leadership position on consumer mowers and no. 2 position on commercial mowers.

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PROFESSIONAL EXPERIENCE Continued

Ames True Temper, Parkersburg, WV – Division Hanson Industries (1986 – 1995), US Industries (1995 – 2000) USI - $350mm manufacturer of lawn & garden and building & construction tools and accessories

Director, Product Research & Development (1986 – 2000)

Reported to President & CEO, Ames True Temper, Member Corporate Coordinating Committee. Managed and directed cross-functional new product development from initial concept, product design and support, through implementation into production for all new product categories including shovels, rakes, hoes, hand tools, shear tools, hose reels, wheelbarrows, lawn carts, spreaders, striking tools, building & construction tools, handles, snow tools, and edging for the homeowner and contractor consumer markets. Led product development group of 12 engineers, designers, model makers, and technicians. Chaired product planning committee meeting on new product project status, engineering changes, and cost reductions. Responsible for $2 - $4 million capital budget for new product tooling and equipment and Engineering expense budget. Responsible for vendor selection, tool build, and implementation for all new product tooling, molds, and equipment. Responsible for CAD hardware and software selection, purchase, training, integration, and upgrades. Directed and coordinated all patent activities with outside patent attorneys. Directed new product design and development activities for Garant Company (Canada), IXL Group (Handles), Woodings Verona (Striking Tool Lines), and Spear & Jackson (England).

Accomplishments (Ames True Temper)

Consistently delivered innovative new products, from initial conception through launch, on time and within budget parameters significantly contributing to company record sales and earnings 6 of the last 7 years in the 1990’s elevating and maintaining company’s position as the clear and recognized new product leader and innovator

New products developed and launched in the 1990’s accounted for over 90% of company sales in 2000

Received approximately 40 patents on various range of products

Implemented CADKEY and SOLIDWORKS 3D solid modeling, Stratasys rapid prototyping, gas assist injection molding process, lean design engineering practices significantly reducing product development cycle times, product tooling costs, and engineering changes to ensure on time and accelerated new product introductions

New product introductions resulted in 1000%+ physical growth of the company’s injection molding operation from 1 facility with 7 presses and 14 molds in 1986 to 4 facilities with 80 injection and blow molding presses and over 300 molds in 2000

Received numerous personal and department awards for excellence in new product design and innovation

PREVIOUS EXPERIENCE

Huffy Corporation, Huffy Bicycle Division, Celina, OH - $350mm world’s largest manufacturer of bicycles

Manager, Product Development and New Product Implementation

Principal Development Engineer

R.D. Werner Company, Greenville, PA, $300mm world’s largest manufacturer of ladders and climbing equipment for the consumer, contractor and building & construction industries

Product Engineer

EDUCATION / PROFESSIONAL DEVELOPMENT

MBA, Management, Youngstown State University

BS Mechanical Engineering, University of Notre Dame

Attended several continuing education courses and seminars on product innovation, new product development, value engineering, concurrent engineering, ergonomics, project management, product liability, plastics, injection molding, CAD, rapid prototyping, lean product design and lean manufacturing

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