Dan Saxe Email & Phone Number

Wisconsin, United States

Die Cast Consultant 30 + years in HPDC aluminum casting automotive programsPart feasibility and design for manufacturing studiesTooling design Run off supportProcess design and developmentScrap reductionDefect analysis and corrective actionsCycle time improvementHigh integrity castingHeat treatment for HPDC Gaging designPPAP process Project management2nd operations Training

Sheboygan, Wisconsin Area

Developed new customers, product line and processes into legacy manufacturing plants. Responsible for all aspects of new product launching; budgets, personnel hiring, training, timelines, consolidated report outs to customers and senior management. Directing the distribution of work activities. Assess product specifications for feasibility and customer cost studies. Executed the industrialization of customer products with implementation through program management, equipment and tooling management, facility readiness and gated program reviews. Represented the company globally through customer tech reviews, briefings, and seminars.• North American Leader for new business development securing new contracts in automotive electrification segment. Represented the company globally for new products and process technologies, resulting in establishing new customers and new product lines.• Developed and successfully launched five new product lines, resulting in $100M per annum of new revenue growth aligned with the company's strategic plan.• Facilitated equipment and tooling expenditure of $60M implementing new facilities, High pressure casting, CNC machining, Welding, assembly, and leak testing lines to produce 300K parts per year.• Managed global team for new product development with implementation execution at multiple locations, resulting in reduced capex spending and reduced timeline. • Fostered innovation projects resulting in improved operational costs, reduced CO2 emissions, and enhancing customer value.• Operated as a crisis manager for critical supply plants spearheading customer communication and ensuring continuous supply of parts, resulting in a stable inventory position, and stable ongoing operations.

Provided customer service and technical design, quoting and cost analysis, tooling design and procurement, product industrialization, and tooling maintenance management. Implemented a culture of innovation to reduce material usage per cycle and improved productivity. Implemented new model launch program management, die cast tooling design and procurement, quoting new programs, including process, tooling, and capital equipment. Practiced the competencies of Automotive standard guidelines.

Equipment design, process design for aluminum castings using experimental processes, product design for manufacturability, and tool design and procurement management. Developed power steering pump for Class 8 heavy trucks with new casting alloy and casting process undercuts that were not permissible in conventional casting processes. Guided experimental process and product development, including disposal core technology, squeeze casting, and custom alloys. As a member of the R&D development team, I was responsible for the implementation of new process and products from the R&D development stage to the mass production phase.

Bmet, Mechanical Engineering

Executive Leadership Training

Education record