Select Achievements

Prevented $20 million in production interruptions by protecting end customer from tier two issues. Attained by taking over tool production and prove-out management operations at the supplier to meet production timelines.
Eliminated over 80% of normal product development time in the development and launch to Afghanistan of the husky lightweight intimate recovery concept (LWIRC) for the British Ministry of Defense.
Eliminated global operation inconsistencies by standardizing engineering tools, processes, and procedures.
Saved $500,000 in data management costs by guiding the transition from 2D drawings to model-based definition.

Devised, created and grew a new technical center in Eastern Europe that reduced the average EU engineering rate by 33%.
Led global PLM strategy team to devise and plan critical deployments.
Facilitated penetration of a billion-dollar market by developing a strategy to expand into Russia via Gaz Automotive.
Developed strategy to create and grow module assembly business unit.

98% drop in the number of emergency work orders through the implementation of visual management.
28% reduction in the time required to execute engineering changes through application of lean devellopement methodologies that eliminated waste and hand-offs in the change process and tools.
33% througput increase in CAD by changing processes and methods.

Established PLM strategy and governance.
Architected & implemented a modern PLM system in 18 months by leading an offshore software development team to customize the system to meet company needs. Migrated over 20 years of product data to ensure complete data traceability.
Upgraded system workflow efficiency by driving the integration between PLM, ERP and purchasing IT systems.
Led PLM selection, Proof of Concept and gap analysis for a start-up OEM.
Led Model Based Enterprise transformation, eliminating 2D drawings while improving access to product data.

1,000% expansion of highly skilled professionals in 14 months in a stringent labor market completed by leading recruitment of high level talent for the top management positions.
Drove consistent and understandable performance metrics by establishing global standards for the competency-based performance management system.

Improved engineering efficiency and integration with purchasing and manufacturing systems by collaborating to implement a global product lifecycle management (PLM) strategy.
67% reduction of management overhead by consolidating testing lab leadership and organizations from three departments into one, improving availability and flexibility.
Drove cultural change to ensure early manufacturing involvement in new product development resulting in smoother product launches at two companies.
Drove collaboration between CAD, CAE, and Tooling Engineering to improve manufacturability of product designs.

Created & managed $14M Opex annual budgets for 28 cost centers in 7 locations across three continents.
Created budgeting methodology and 12 month rolling forecast methodologies for a Chinese start-up.
$2.2 million revenue product improved by guiding the redesign of key HTT vehicle to meet US Navy requirements.

Trained Ford/Otosan JV engineers on Project Management techniques to work autonomously within the Ford product development system.
Advanced opportunities for a joint venture proposal in India with the Hero Motorcycle company by evaluating products to identify notable methodologies to align capabilities with the JV partner.
78% reduction in training time for all North American technical personnel on the project management system by developing a process of isolating required elements and eliminating unnecessary training content.
North American trainer for company's product management system.

Conceived, built and patented wheel alignment tooling that reduced warranty by $5,000,000 per year.
Developed first in the world suspension system that allowed building front wheel drive and rear wheel drive vehicles on the same platform saving over $500,0000,000 in tooling.
$10 million BOM cost reduction, 7 kg weight reduction, and improved vehicle dynamics and off-road capability achieved by formulating a new suspension system.
$2 million decrease in tooling cost and a 12% reduction in variable expenses accomplished by efficient redesign, prototyping, and the launch of an EV, completing the project in eight months.
Created the impossible by packaging an all-wheel-drive system into a vehicle once considered unachievable.
Patented the use of ultra-high strength steel for suspension components to expose the firm to lightweight, higher margin solutions.

$4 million vehicle project taken from competition while working in a hostile environment by forming a small team inside the competitor’s building and taking over engineering and PM leadership.
$5 million won in a new product for a Chinese tier one by providing on-site technical / project management expertise.
$75 million in unplanned business won as the first award from this customer in more than five years.
40%+ return-on-sales for engineering services to non-traditional OEMs attained by reducing the people required to execute services billed at a higher staffing rate.

Dozens of Technical Presentations given to customers to support new business development.
2008 Great Designs in Steel presentation to 600+ people. Download the Slides
Presentation at Aras ACE 2015 conference detailing Key Safety Systems PLM journey. Watch the Presentation

Awarded the Henry Ford Technology Award, Ford’s highest award for technical achievement.
Ford Significant Achievement Award for development of a first in the world vehicle platform that saved over $500,000,000 in tooling costs.
US Patent - Vehicle suspension control arm and method
US Patent - Apparatus and method for centering a vehicle steering wheel
US Patent Application - Method for making a non-driving vehicle axle beam

Contact Me