Anthony Modica Email & Phone Number

Royal Oak, Mi, Us

Detroit, Mi, Us

- Responsible for pursuit and execution of a 3-in-1 electric beam axle project for a heavy-duty truck platform with major OEM.- Successfully managed the customer relationship and concept development of HD eBeam, which led to a project award for AAM.- Developed and maintained engineering development (ED&D) budget for the eBeam project with close alignment from cross-functional engineering leaders and Product Engineering leadership.- Lead development of a cross-functional project team with a well-executed project kickoff.- Responsible for technical leadership of a large cross-functional project team, as well as staffing for the system engineering team.- Successfully completed Dyno Calibration and Mule prototype designs, which are in process of HW procurement and build.

Friedrichshafen, Baden-Württemberg, De

- Responsible for departments of Resource Management, System Management, and System Engineering for Electrified Powertrain Division in Region NA.- Responsible for successful execution of electrified system level and standalone sub-system level projects for entire Electrified Powertrain portfolio in NA, including Conventional/Hybrid Transmissions, e-Axles,e-Beam, Power Electronics, E-Motors, and Electronic Controls.- Responsible for technical leadership and staffing for electrified system and standalone sub-system acquisitions.- Responsible for resource planning (people, equipment, new locations) for R&D in region NA, as well as globally for project staffing.- Product Line EA (Axle Drives, e-Beam) R&D responsible for Region NA, which includes strategy, budget, staffing, and technical escalations.- Responsible for growth of the electrified system responsible team and capabilities within the region.- Responsible in region for product benchmarking and electrified powertrain demo vehicle projects.- Member of leadership team responsible for reorganization of North American R&D team due to merging of E-Mobility and Powertrain divisions into one division, Electrified Powertrain Technology.

Friedrichshafen, Baden-Württemberg, De

Friedrichshafen, Baden-Württemberg, De

- Responsible for development and validation of axle drives, including mechanical design, acoustics and bench testing, for projects within the region NA.- Responsible for initiation and growth of Application Engineering team, as well as design and test capabilities in region NA.- Recruited, coached, and led staff of Development Engineers, NVH Engineers, and Test Engineers.- Dotted line responsible for North American manufacturing plant Resident Engineers, regarding vision for growth and capabilities, as well as for technical escalation topics.- Planned and launched a 3-motor dynamometer and rotary fatigue tester at the ZF North America, Inc. Technical Center to support independent drive unit and beam axle development validation in NorthAmerica.- Self-developed and fully launched an improved test request and tracking system with the ability to track test utilization for KPIs in MS SharePoint.- Responsible for benchmarking and new technology demo vehicles for product line axle drives at industry events in region NA.- Digital Ambassador for E-Mobility Division responsible to represent North America regarding ZF digitalization efforts and tracking innovation.

Friedrichshafen, Baden-Württemberg, De

Engineering Manager and Program Manager for Independent Drive Axles and Light Duty Beam AxlesZF North America, Powertrain Division - Axle Drives, Northville and Marysville, MI• Previous description still applies for gear and axle manufacturing plant Engineering Manager. • New additional role: Engineering Manager for North American Application Engineering team responsible for supporting development and validation of axle drive projects, including acoustics and testing. • Manage staff of 4 Development Application Engineers and 3 Test Engineers. • Responsible for growth of North American Application Engineering team capacity and development capabilities. • Responsible for planning and implementation of a new dynamometer to support independent drive unit and beam axle development validation in the US. • Self-developed and fully launched an improved test request and tracking system with ability to track test utilization per test for KPIs in MS Sharepoint. • Responsible for US-based benchmarking and new technology demo vehicles for BU at industry events.

Friedrichshafen, Baden-Württemberg, De

Engineering Manager and Program Manager for Independent Drive Axles and Light Duty Beam Axles• Manage staff of 7 Resident Engineers and 2 Engineering Interns / Co-ops. • Lead Resident Engineering team responsible for the launch and life of program for independent front and rear drive units, rear beam axles, axle and vehicle acoustics, axle teardown analysis, and prototyping.• Manage Acoustic Engineering team and Road Test facility for axle NVH testing and “in vehicle” acoustics.• Oversee Program Management on all programs, including product gate release process from concept to launch.• Developed project plans and successfully launched a new “ground-up” building expansion to house the Engineering Axle Lab for in-vehicle acoustic road test and investigative teardown analysis.• Work in concert with VP of Engineering and Sales Managers to identify and secure new business.• On the core launch team during initial product launch in 2010 and have been a major player during all product launches to date. In the 5 years since launch, we have secured and launched 6 major platforms, on time and under budget, exceeding annual volumes of 1.5M axles per year.• Successfully managed a rapid response team that launched a new supplier from purchase of new equipment to PPAP / SOP in 7 weeks (normally a 30-week lead time for this type of launch) to avoid a major supply issue.• Self-developed and fully launched improved global systems for Engineering Deviations, Engineering Change Management, Lessons Learned and Problem Solving, Dimensional Lab Requests, Road Test Analysis, Warranty and Test Teardown Lab, and Test Vehicle Useage in MS Sharepoint.

Friedrichshafen, Baden-Württemberg, De

Engineering Supervisor and Program Manager for Independent Drive Axles and Light Duty Beam Axles• Hired a staff of 6 full-time Engineers and 2 Engineering Interns / Coops. Previous structure was only 3 Engineers reporting directly to Plant Manager.• Lead Resident Engineering team responsible for the launch and life of program for independent front and rear drive units, rear beam axles, axle and vehicle acoustics, axle teardown analysis, and prototyping.• Oversee Program Management for all programs, including product gate release system from concept to launch.• Designed and launched an engineering teardown area, fully equipped and staffed, for prototype builds, warranty, post durability, and quality inspection analysis.• Manage Acoustic Engineering team and Road Test facility for axle NVH testing and in vehicle acoustics.• Developed Co-op program for the ZF Marysville site.• Reorganized and restructured engineering parts crib and developed an inventory tracking system via Excel VBA.• Created a new engineering deviation program for the plant via Excel VBA.• Developed a part quality dashboard, via Excel VBA, that is capable of mining data in seconds to report trends and proactively identify potential issues.• Successfully managed a rapid response team for a major “pass through” quality field issue and co-developed a massive offline rework operation, saving over $25M in product.• Co-developed and launched a global system in MS Sharepoint, to track and store data for all warranty returns, investigative teardowns, and vehicle road tests. Has capability to auto-generate reports, track progress and KPIs.• Created a new Engineering Change Management tracking program for the plant via Excel VBA.

Friedrichshafen, Baden-Württemberg, De

Lead Senior Resident / Liaison Engineer and Program Manager for Independent Drive Axles• Program Manager and Lead Engineer for all independent front and rear drive axles used in multiple major luxury brands, demanding the highest level of quality and innovation.• Managed the successful launch of 5 major products for 2 different automotive OEMs from kickoff to production.• Played a vital role in commissioning three new drive unit assembly lines for an on-time production launch.• Attended weekly design reviews with the customer throughout the entire span of each project, from kickoff to launch and beyond, as an engineering liaison for the German-based design team and as the Project Leader.• Host and organize monthly program reviews with customer Senior Management.• Supported Purchasing and Supplier Quality departments in developing a strong supply base and assisted in supplier process approvals, both locally and overseas.• Led Process Sign-Off (PSO) / Production Part Approval Process (PPAP) efforts and successfully achieved full customer approval.• Coordinated and executed prototype and pilot builds for validation bench testing and customer vehicle testing.• Developed and implemented a full scale warranty teardown area in the new plant.• Provide daily engineering support to manufacturing and quality departments.• Represent Engineering at suppliers and customers to lead problem solving efforts regarding product related issues.• Compose necessary process/product deviations to engineering specifications, while maintaining product integrity.• Review and coordinate engineering change requests, utilizing internal engineering and business support processes.• Ensure correct technical documentation and bill of materials are continuously up to date and readily available, in order to maintain product integrity and compliance to TS-16949 certification.

Detroit, Mi, Us

Metal Formed and Machined Components Business Unit Lead Design and Release Engineer. Cost Reduction Coordinator for all plants.• Resident Product Engineer for all forging and machining plants, which produce net shape differential and transmission gears, axle shafts, ring and pinion gears, and precision driveline and transmission components.• Resident Product Engineer for Steering Linkage Division and Harley Davidson Tri-Glide Axle.• Performed daily product support activities for manufacturing, production, and quality throughout MFPBU.• Develop, validate, and release product design enhancements to further improve quality and cost.• Lead engineering cost reduction efforts, which produced over $30 million in savings since 2005.• Successfully led redesign and validation of a rear axle carrier casting to allow for a die cast process, which resulted in over $600,000 in annual savings.• Led validation efforts for transition of mechanical forging presses from Tonawanda Forge to Cheektowaga Manufacturing Facility.• Developed and coordinated validation efforts for many steel and sub-component supplier resources, due to the economic downturn, and successfully obtained all necessary customer approvals.• Support new product launches at MFPBU plants to facilitate flawless execution.• Maintain product integrity by providing engineering analysis and validation on all applicable design changes and enhancements.• Coordinate and oversee all prototype builds for product design changes.• Manage MFPBU Product Engineering project and prototype budget.• Determine root cause on warranty investigations using problem solving techniques and make corrective action recommendations.• Assisted in net shape differential gear development.

Detroit, Mi, Us

Product Engineer and Design Release Engineer for GM Light and Heavy Duty Beam Axles• Resident Product Engineer for all Western New York plants including, Buffalo Gear & Axle, Tonawanda Forge, and Cheektowaga Manufacturing Facility.• Responsible Product Design Engineer for mid-size truck rear axles and various forged driveline and suspension components.• Successfully designed, validated, and implemented 2009 model year mid-size truck rear axle for GMT355 program with Electronic Stability Control.• Managed numerous product improvement and cost saving projects for axle components.• Led engineering cost reduction efforts, which produced over $25 million in savings since 2005.• Coordinated all prototype axles and validation testing to qualify process or product enhancements.• Presented written and technical communication internally and to external customers.• Provided technical direction to CAD designers, FEA engineers, manufacturing/process engineers, suppliers, purchasing, analysis & test engineers, etc.• Managed Product Engineering Department project budget and cost analysis process.• Performed several studies using Robust Engineering techniques to determine best practice for design and manufacturing of ring gears.• Quality Systems Action Committee representative for Product Engineering department.• Lead warranty investigation teams to determine root cause and corrective actions using Shainin problem solving strategies and techniques.• Supported company during work stoppage by operating CNC lathes, performing quality inspections, and managing material distribution.

Fort Collins, Co, Us

Designed and tested hydraulic and pneumatic servo controls used in commercial aircraft applications.• Performed daily product support activities and provided technical expertise for various hydraulic and pneumatic servovalves.• Authored various test procedures and specifications. • Planned and coordinated product design improvements which have improved reliability and cut costs.• Managed and coordinated new valve design from conceptualization to qualification. • Contributed in the successful transition and implementation of servovalve business from location in Buffalo, New York to corporate headquarters in Rockford, Illinois.

Fort Collins, Co, Us

Assembled and bench tested electromagnetic servo valves for commercial aircraft APUs and air pressure systems.• Assembled and tested diversified electromagnetic servo-controls involving complicated calibration and tuning to meet requirements.