Coached, mentored and developed a team of seven Process Engineers and five Process Technicians in a fast-paced environment to provide custom, innovative finishing solutions for manufacturers in the aerospace, automotive, defense, medical and consumer retail industriesProvided strategic direction for a Maintenance Department of 13 Technicians, Maintenance Manager & Planner to successfully maintain daily processes and implement strategic facility improvements to realize corporate directives for revenue growth. Responsible for operational budgets (personnel & material expenses) in excess of 3.5MMManaged the launch of a new facility clean room installation and spray process to support the application of specialized aerospace primers and two new plating processesFacilitated the transfer and deployment of Engineering and Maintenance resources from a functional-based organizational structure to a product-focused organization to achieve corporate metrics for improvements in lead-time, productivity & quality

Managed a team of five Manufacturing Engineers to implement process improvements for various metal stamping, MIG/resistance welding, assembly and friction material manufacturing operations.Instituted and managed a corporate Engineering Co-Operative Education program to develop and recruit young engineering talent for the organization, with students participating from three, local universities.Coordinated Engineering and Maintenance efforts to launch a facility-wide, preventative maintenance program for over 140 pcs of equipment using a cloud-based ERP system (PLEX)Initiated a corporate program to track overall equipment effectiveness (OEE), resulting in average productivity improvements of 10% across four Business Units within a 12 month periodOversaw and approved new equipment purchases and researched new equipment technology to develop strategic plans for maintaining industry competitive process capabilities

Responsible for product design control and brand development of a unique, heavy-duty, aftermarket synchronizer product line.Served as final design authority for implementation of design changes and introduction of new products, pertaining to heavy duty synchronizer productsDeveloped a plan to expand in-house testing resources, including the redesign and reconstruction of a test stand for the evaluation of new and existing products.Evaluated and analyzed new process and product technologies to identify opportunities to enter new market segments and develop new product offerings.

Managed the implementation of an electric vehicle transmission assembly line with 1.07 million in total, working capital; including specification & purchase of equipment, development of operator work instructions, plant floor layout and local launch management support.Coordinated the processing and delivery of prototype and pilot samples for prototype builds at BorgWarner’s powertrain technical center.Organized and led design for manufacturability and design for assembly reviews between engineering and manufacturing teams to improve manufacturability. Coordinated facility level transfer of BorgWarner’s synchronizer product line (equipment/tooling assets and intellectual property) to achieve corporate goals for product portfolio downsizing during the 2009 recession.

Analyzed transmission layouts and specified synchronizer systems for dual clutch transmission programs within the People’s Republic of ChinaManaged six Chinese synchronizer programs requiring development of detailed system package drawings, management of prototype procurement and customer visits to ChinaChaired weekly program review meetings between engineering, sales and applications engineering teams in China, Germany, the US and Wales (UK)Refined and verified synchronizer performance calculation methods to specifically address the unique operating environment of dual clutch transmissions with collaborative input from advanced product engineers in Auburn Hills, MI

Completed synchronizer system performance and tolerance stack calculations, conducted sub-system validation tests and completed a design review by failure mode (DRBFM) analysis for a BorgWarner transfer case program with Toyota Developed and implemented standard design practices, based on automated macro-enabled spreadsheets, and parameter based 3D models, which reduced total time and engineering resources required to develop system designsLed the design, development and validation testing of a synchronizer system for an experimental, off-highway transmission for CATERPILLAR Inc. generating over $400,000 in revenue for the product engineering department over two yearsConducted research & testing as part of a cross functional team that developed a carbon-based composite friction material optimized for synchronizer applications

Developed parametric model files in Pro-Engineer that automatically generated 3D models and 2D drawings of synchronizer components based on a set of standardized geometrical inputs in tabular format to reduce design time by 80%.Designed prototype components, managed material procurement for the completion and delivery of prototype hardware and presented engineering test results to customers for various synchronizer & limited slip differential programs.Conducted finite element analysis (FEA) and dimensional analyses on synchronizer components as part of the design development processDeveloped, refined and implemented test procedures for the evaluation of synchronizers and multiple disc clutches on in house test equipmentLed and directed a team of 3 engineers to analyze conceptual designs for advanced synchronizer systems as part of a 3 month development program with General Motors Europe using a €100,000 budget

Worked in Bremen Germany for 3 months (Jan-Apr. 2001) studying European business culture and manufacturing methods for thermal flame spray used in European automotive applicationsReviewed print specifications for European synchronizer & friction plate applications using metallic friction linings with engineers from German sister company (Euroflamm) and recommended design changes to optimize system performance using carbon friction materialsDeveloped and implemented an effective system for estimating manufacturing costs that was used to bid synchronizer bonding operations in North America Managed the procurement of raw materials for prototype builds and constructed prototype clutch packs for limited slip differentials used in customer vehicle tests in North America and lab bench testing Europe