Manager Engineering

Alfred J. Kosmal

*** *. *** **., ***** Vernon, WA. 98274

360-***-**** ********@*******.***

Total Quality Management~ Technical Director ~New Product Development ~ Program Management

Strategic Planning ~ Policy Deployment ~ Program Management ~Engineering Design ~ Manufacturing Engineering Quality Management System Implementation & Management

Dynamic, award winning leader with outstanding success at forming, motivating, and managing effective multi-discipline product development teams. Multi-functional managerial skills and demonstrated experience with Six Sigma tools and methodologies. Skilled in technical and financial responsibilities, managing cross-functional teams, and managing budgets and schedules.

Company leadership responsibility for setting the technical direction, meeting customer expectations regarding both the development of new products and the associated manufacturing processes. Company champion for TQM/Danaher Business system programs.

Professional Recognition

• Granted, U.S. Patent, “Temperature Compensated, Easily Installed, Bolt-on Strain Sensor,

• Granted, U.S. patent “Pre-Straining apparatus and Method for Strain Sensors

• Patent Applied for “ Method and Apparatus for determining the weight of the contents of Vessel, Silos and bins by measuring the stress level in the vessel foundation”

• Patent Applied for “Method for correcting temperature errors in strain gage sensors and sensing systems.”

• Process Magazine’s 2002 Product of the Year Award for the ORB 2.0

• Recipient, Certificate of Recognition from Powder and Bulk Solids for professional and technical contributions to the field.

• Published, “The Silo Solution” in Powder and Bulk Solids and Weighing and Measurement magazines.

Professional Experience

Index Sensors & Controls Stanwood, WA. 2004 – 2012

Director of Engineering/Program Manager/ Index Executive Leadership team

• Leadership (technical and business management)

• Direction for the Engineering, Manufacturing Engineering, and Quality teams. (streamlined the product/process development by integrating these previously silo’d functions into one goal oriented team)

• Team building

• Responsible for the definition, interviewing, hiring, training and direction of the teams.

• Based on clearly communicated business/customer requirements, team/team member expectations in alignment with the requirements.

• Identify measurable objectives/key performance objectives

• Quality, Delivery, Cost, Growth

• Manage the team (direct and indirect resources) based on plan vs. actual per communicated expectations/measurable objectives.

• Product/Process Management

• Product Development Process (Phase Gate)

• Evaluation of new product opportunities to business objectives, customer requirements

• ROI analysis

• Balance resource capacity

• Plan, schedule, and control complex projects

• Allocate best resources and track progress

• Monitor and visualize project performance versus plan

• Communicate status/measures of plan vs. actual program/project performance at all phases, countermeasure as required.

• Prepare project schedules (M’soft project)

• Set and manage project goals, team/team member objective and responsibility.

• Worked directly with key vendors to ensure that requirements are met.

• Expert-level experience with the design and fabrication of electro-mechanical devices and parts using machining parts, sheet metal, plastics (molded, formed and machined), printed circuits, enclosures, etc.

• Customer Satisfaction

• Liaison for all matters related to product design, quality, specification and application

• Evaluation of RFQ’s (technical and business)

• Management of internal/external resources to ensure quality, delivery, cost and customer satisfaction goals are met.

• Ensure all standards (ISO, SAE), plus specific customer requirements (Cummins, Caterpillar, etc.) are met.

• Continuous Improvement Programs

• Goals, measures and incentives to align all activities with the Corporate Strategic Plan.

• Instrumental in forming the team(s) responsible for the implementation of improvement priorities. (initially consisting of key team members, familiar with the Danaher Business System, that reported to me, directly or indirectly, during my years at Kistler-Morse)

• Key performance, both External and Internal was benchmarked and improvement objectives were implemented as follows:

• On time Delivery (OTD) improved from 70%-80% to 98%+

• Warranty Incident Rate (WIR) reduced to >200ppm

• Cost of Poor Quality (COPQ) reduced from 4-5% to 1% of revenue

• First pass yield (FPY) reduced from 80Kppm-90Kppm to >10Kppm

• Via the introduction of key performance indicators (KPI’s) and a return on investment (ROI) focus. I developed within the quality, technical and manufacturing groups an understanding of the relationship of actions to financial results.

• Introduced proven methodology for problem solving such as Cause and Effect Diagrams, 7-Step Root Cause Analysis, etc. to provide structure and also to expedite these activities.

Kistler-Morse Corporation (a Danaher Company) Bothell, WA 1984-2004

Director of Engineering/Operations (1999 – 2004)

• Leadership (both technical and business management)

• Direct the Engineering Department, New Product Development Teams, Manufacturing Engineering

• Strategic planning

• Market and technical trend research

• Create and Articulate vision

• Develop and communicate strategies

• P&L responsibility

• Managed, as a leadership team member, the overall company business and financials, as well as departmental budgets.

• Continuous Improvement

• Drive the Danaher Business System and 6 Sigma quality controls throughout the organization.

• Managed an Engineering Department

• Implemented goals, measures and incentives to align engineering with the Corporate Strategic Plan.

• 100% OTD of New Products.

• Quality, delivery, and Cost goals met 100%

• Commercial goals met 100%

• Introduced 6 Sigma problem solving methodologies.

• Responsibility for the output of the Custom(er) Engineering Group

• Worked directly with customers to understand their needs and developed custom products/systems to meet them.

• Managed the “Custom requirement” from fact gathering, cost/time estimates through delivery. Worked directly with Sales department and customers to define product/system requirements.

• Provide budgetary quotes for cost/time to design and fabricate weighing systems requiring non-standard content.

• Increased the custom sales to 30% of total sales. Much of it incremental business.

• Managed an Operations Group of 20

• Improved Overall Factory First Pass Yield from over 200Kppm to under 75Kppm.

• Introduced “cost of poor quality’ (COPQ) analysis methods to define the return on investment of Manufacturing Engineering programs and to prioritize them from a cost/benefit standpoint.

• Developed and implemented process(s) and process improvements and managed results via key performance indicators/countermeasures.

• Via key performance indicators (KPI’s) I developed within the technical and manufacturing groups an understanding of the relationship of actions to financial results.

• Technical

• Developed new products that were crucial to the growth of the company.

• Many patents awarded to my Engineering group, two awarded to me personally.

• My group developed the Orb 2.0, which was awarded the “2002 Product of the year” award by Process Magazine. This design was based on the concept of a “Smart Communication J-Box” that I proposed as a new product idea.

• The introduction of new products were primarily responsible for doubling the top line revenues.

• Recognized as an expert in the field of industrial weighing systems and applications.

Early career progression at Kistler-Morse

Engineering Manager –Transducers & Custom (1993 -1999)

Engineering Manager ~Custom & Applications Engineering (1990 -1993)

Engineer II (Custom) (1987 -1990)

Design/Documentation Supervisor (1984 -1987)

Additional early experience

Electro-Flo Mechanical Designer Redmond, WA 1982 -1984

Pacer Corporation Design/Documentation Supervisor Bellevue, WA 1980-1982

Resource Control Electro-Mechanical Designer Bellevue, WA 1979-1980

Fermi National Accelerator Laboratory Electro-Mechanical Designer Batavia, IL 1977-1979

North American Tab Assistant Manager of Technical Services Wheaton, IL 1975 -1977

Strom Engineering Printed Circuit Layout Design Naperville, IL 1974 -1975

GTE Automatic Electric Technical Illustration & Printed Circuit Layout Design Northlake, IL 1973 -1974

Education/Additional Training

Chicago Academy of Fine Arts BFA. 1973

Emphasis on Industrial Design

Danaher Business System

Six Sigma Leadership ~ Value Stream mapping

Strategic Planning ~ Policy Deployment ~ 5S ~ Kaizen ~ Standard Work ~

Product Development ~ Project Management

Leadership/Team Building

Leadership/Team Building workshops with Dr. Jack Baker

Leadership Institute of Seattle workshops ~ Results Focused Communication ~

Interact - Quality Workplace Relations

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