Summary: 12 years of manufacturing experience (Quality, Process, Launch). Expert in manufacturing statistics (Six Sigma, SPC, Control Plans, FMEA). BS in chemical engineering (University of Michigan, 1997).
Experience
Fisker Automotive, Anaheim, California 2010 - 2012
Manufacturing Engineer
Provided engineering support for the manufacturing launch of 2 electric hybrid cars: the Fisker Karma and the Fisker Atlantic. Developed performance specifications for all exterior paints. Developed plant process controls for color, appearance, and film build.
• Led the paint supplier selection process of all paint materials (parts and body) to be used on the Fisker Atlantic (originally scheduled to be manufactured in Wilmington, DE).
• Assisted contract manufacturer in Finland launch 8 color paint pallet on the Fisker Karma body.
• Assisted part suppliers for the Fisker Karma launch an 8 color paint pallet. Suppliers located in Germany and Mexico.
• Led design for paint shop manufacturing (DFM) activities (electrocoat/paint and static sealing processes on vehicles), using AutoCAD viewers.
New United Motor Manufacturing, Inc. (NUMMI), Fremont, California 2007 - 2010
Senior Plant Engineer
Provided engineering support for the paint circulation and robotic paint processes used to manufacture 1,000 Toyota Corollas daily.
• Led $150K project (cited in the 2009 Toyota Environmental Report) to implement new manufacturing tool which eliminated ergonomic strain on assembly workers and exposure to cleaning solvent VOC.
• Led $378K annual cost savings continuous improvement projects which reduced robotic cleaning solvent usage by 300 gallons daily. NUMMI awarded my team a Suggestion Prize for results.
• Led robotic paint application setup for the launch of 2 new vehicles. Ensured the eight new paint colors met Toyota Quality Standards for paint appearance and launched on schedule.
• Assisted with launch of a new Henkel purge solvent which reduced environmental impact by 10% (VOC reduction).
Ford Motor Company, Dearborn, Michigan 2001 - 2007
Manufacturing Development Engineer
Led assembly plant paint shop launches of the 2007 Ford Edge and 2005 Ford Mustang. Worked with vehicle designers to ensure new vehicles were compatible with manufacturing processes. Led worker training at manufacturing site. Led cross functional PFMEA teams for new manufacturing processes. Developed manufacturing control plans and wrote work instructions. Presented launch status to senior management.
• Led $1M projects to enginee...
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