Bob Rath Email and Phone Number

Rath Product/Process Development is a consulting service that specializes in:* Product Improvement Product Differentiation Value Add Opportunities Cost Reductions* Process Improvement Lean Operations Manufacturing Cells Automation* Remanufacturing Core Management Single Bills of Materials Material Management Logistics Salvage Operations Environmentally friendly cleaning operations* Employee  Engagement Lean training Development* Customer Support Brand Value Contract negotiations* Quality  Formal Systems Informal Systems Accountability* Engineering Process Improvement Market Strategies Speed to market* Solutions that are: 1. Effective  2. Simple  3. Executable

 Program Manager for the Power Systems Business which was a full range of natural gas engines for power generation primarily in standby and prime power applications.  Program Manager for the New Energy Business which was the sale and development of Li-Ion batteries and battery powered Power Units designed to replace internal combustion engines for reduced emissions. Directed the successful launch of the Li-Ion Battery Program generating over $1 million of annual revenue. Led the implementation of safe battery storage at PSI. Named as an inventor on the Power Unit patent application. Composed several articles in the PSI internal newsletter highlighting the accomplishments of fellow employees.  Recognized by engineering that the Power Unit was one of the fastest launches of a new product at PSI.

Program Manager for large natural gas engines and battery programs. Successfully coordinated the launch of 3 different engine series with 9 different engine displacements focused on standby and primary power for commercial buildings and hospitals. Supported continuous improvement projects on existing engines in the PSI portfolio. Recently coordinated the launch of industrial batteries for applications such as ice machines and material mover applications. Most recent accomplishment was the successful launch of a battery powered electric motor application in a woodchipper to displace gas and diesel engines for reduced emissions and compliance in certain emission reduction areas.

Responsible for the overall product quality of railroad tank can products. Maintained AAR (American Association of Railroads) certification. Sustained FRA (Federal Railroad Administration) certification. Maintained ISO 9001 certification. Reduced first part inspection by 90%. Installed improved inspection tools to increase throughput and reduce downtime. Supported the implementation of the remanufacturing program.

* Led $800M Engine Aftermarket Business* Supported and assisted with the development of the multi-year contract to supply 1,500 remanufactured engines to a major railroad.* Implemented high-quality Locomotive Engine Remanufacturing in La Grange, IL* 0 to 100 remanufactured engines in 10 months starting in an empty warehouse * 1 remanufactured locomotive engine per day * $1 million revenue per week * Integrated remanufactured engines into new engine assembly line* Led $150 million aftermarket remanufacturing business with 35% margins* Developed and implemented innovative salvage techniques* Implemented emissions reduction programs for all EMD engines* Introduced fuel consumption reduction programs* Directed EMD Brand and promoted the value of branding* Participated in the development of both Dynamic Gas Blending (DGB) and Direct Injected Gas (DIG) natural gas engines.* Contributed to the Tier 4 Engine Development Program.* Interfaced with Caterpillar Remanufacturing to develop additional salvage opportunities.* Developed turbocharger cost reductions of $2 million the first year and identified opportunities for another $2 million/yr. savings.* Supported international engine component remanufacturing programs.* Developed new cylinder head salvage process to salvage $3M of cylinder heads to meet delivery schedules and salvage a $30M international contract.

Top level position with full P&L responsibility for a 135-person 24 hour/day operation growing the business from $24 to $35 million in two years* Transitioned from a single captive customer to a multiple diverse customer operation* Increased sales 45% utilizing 15% increased manpower and 15% additional capital equipment* Reduced manpower 30% on two existing manufacturing cells* Purchased $3 million of equipment for $1 million which increased throughput 25% and reduced manpower 45% in two high volume cells* Implemented one piece flow in two cells* Implemented multiple tasking machines* Initiated two additional heat treat processes* Proposed alternate materials to reduce cost without sacrificing strength or durability* Reduced perishable tooling costs by 30% in two years

Consulted at Giddens Industries and revamped the Aerospace bid process to reduce 3 month engineering backlog to one weekCompleted routings on time to support Operations to eliminate engineering backlog and meet production schedules

Member of the executive management team with responsibilities in the USA, Brazil and Argentina. Developed the strategic quality and reliability systems for seven manufacturing sites which included two foundries and served for two years as Director of the $300 million revenue I-6 business unit with full P&L responsibilities.* Reduced first year warranty by 82% after new engine launch by creating an alliance with Ford that resolved critical design issues in less than 90 days after identification* Recipient of the Ford Award, “Recognition of Achievement – Warranty Reduction” by supporting the Ford Quality Center problem solving team and implementing product improvements totaling $24 million* Enhanced the new product development system by implementing a process to monitor, measure and predict quality performance of new products to reduce first year warranty costs* Led the 2,800 employee division’s cultural and organizational program to secure QS-9000 registration* Initiated the Divisional Black Belt Program yielding $15 million net savings in the first year to eliminate chronic problems using the six-sigma process* Reduced customer delivery defects from 30 to 18 per 1,000 in 10 months on a complex product line* Negotiated and defined the quality requirements in the 10-year $12 billion Ford Diesel Engine Supply Agreement that insured a long-term alliance with Ford Motor Company* Performed vehicle field tests to predict new product quality and minimize first year warranty issues* Secured Board approval to purchase a surplussed engine transfer line at 20% of the original cost for the 2004 engine program saving the company approximately $50 million

* Developed sales in Canada, Australia, South America and Asia, which increased revenues 35%* Delivered 61% of the profits on 40% of revenues for Detroit Diesel Remanufacturing Corp. in a highly competitive market by focusing on reducing material costs and satisfying customer requirements* Grew revenue from $3 million to $38 million and profits from $30,000 to $4.5 million in a declining market by understanding and resolving customer issues and measuring key performance criteria for the business* Led the organization to achieve industry recognition as the first remanufacturer to achieve Class A MRP II worldwide by focusing the organization on key disciplines to improve the entire business process* Implemented a 40/day transaxle remanufacturing operation in a separate facility* Grew the business 30% by acquiring two competitors to integrate a new product without adding floor space* Achieved sole source worldwide production of remanufactured injectors and turbochargers by being the lowest cost and highest quality producer* Reduced annual employee turnover from 60% to 13% by engaging the workforce in improving the workflow and interfacing with customers* Reduced product lead-time from 14 days to as little as three hours by eliminating process flow issues to grow the business without adding floor space* Eliminated annual physical inventories

RTD (Regional Transportation District), Denver CO 1977 to 1979Warranty Coordinator /Resident Engineer for 300 new transit buses and part time Unit Overhaul Shop Manager

Diesel and Gas Turbine Engine Service Tool Design Engineer and Product Support Manager