Michael A. Gelbke, Pmp, 6Σ Blackbelt, M.Sc. Mfg. Eng. Email & Phone Number

Greer, South Carolina, US

• Process Analyst – Global Warranty SolutionsCompleted contract analyzing BMW global warranty claims and steering Module Leaders towards corrective solutions. Full time caregiver to terminally ill father requiring.
• Directly supported industrialization of prototypes and their integration into the Spartanburg plant from concept to series full production. This included planning and tracking process series validation, supplier.
• Solely responsible for limited edition BMW components, e.g., “Black Fire”, “Dark Shadow”, “Collector’s Edition” X-5 & X-6 vehicles.
• Facilitated supply-chain workshops and deep-dive supplier quality, delivery, and cost reduction activities.

Charlotte, North Carolina, US

Managed process engineers, technicians, quality manager, quality engineers and laboratory analysts for a 324,000 sq. ft. ~ 210+ employee mfg. site producing over two (2) million lbs. per month of non-woven textile products for the medical, hygiene and industrial industries.

Aurora, Ontario, CA

• Managed Sales, Pricing, P&L, Delivery, Automation & Capital, Quality/Regulatory Compliance and Program Management for Mercedes, BMW, Volkswagen manufacturers at Magna Int'l. in Knoxville, Tennessee, United States.
• Successful annual profitability improvements of USD$ 1.1 million/year through customer management, product & material pricing negotiations and creative cost reduction activities.
• Directed multiple projects, each to USD$4.3 million, mitigated new technology risks for innovative structural component hot stamping, laser trimming and assembly operations. All B-2-B portal systems familiarity.
• New product estimating and formal quoting led to Mercedes and BMW program awards.
• Daimler and BMW supplier B-2-B systems, inc. Program Launch, Logistics and Quality portals.
• VDA 6.1 [Verband der Automobilindustrie] and TS-16949 Process Auditor Certification

Nanterre, Île-de-France, FR

• Directed the activities of a cross-functional team in establishing a new mfg. site for BMW seating systems. Scope also included product, processes, layout, capital to launch BMW X-5, X-6 and Hybrid vehicles from design.
• Re-designed and retrofitted over 53 implemented designs to service a customer base with over 7,000+ product variations representing over USD$ 220 million annually.
• Built credibility & trust through open, direct communication and presentations as "principle liaison" between various internal/external supplier & BMW customer groups in Europe and North America. Worked in multiple.
• Managed USD$ 5.1 million capital budget and technical specifications to acquire new processes and facility, e.g. production lines, shipping systems on schedule and budget while delivering exceptional initial quality.
• Attained Faurecia Excellence System product & process scores of 98% and 97%, in addition to 98% ergonomic score.
• Accelerated output post start-up by increasing daily volume from 460 car sets per day to up to 530 car sets per day.

Dubai, Dubai, AE

• Intertec Systems, LLC was a joint venture of Johnson Controls and INOAC of Japan producing instrument panels and consoles in facilities: United States, Canada and Mexico.Advanced Engineering Manager responsible for.
• Introduced innovative capital justification systems, cost tracking, equipment design and specification with 0 ppm (part/million) and 100% efficiency targets 30 days post launch.
• Managed USD $27 million capital budget and generated over $8 million in savings.
• Added innovative $5.1 million powder casting operation and new building to Ontario facility, in addition to paint systems, molding presses, and state-of-art laser perforating operations that aid passive restraint air.
• Mentored and influenced engineering team to increase program delivery despite a 20% reduction in staff.
• Developed a creative manufacturing layout that optimized material flow and production control and reduced floor space of one program from 27,000 sq. ft to 9,800 sq. ft. Developed a creative manufacturing layout that.

AGM, Inc.-Owner of Granite & Marble Import Business. Established business plan, accounting systems, purchasing, marketing plans, logistics and sales of commercial and residential projects in Orlando, Florida.PDP, Inc., Angell Construction, Inc. — Business Consultant for $10 million commercial, residential and construction company in Tampa, FL. Identified.

• Directed the activities of 42 professionals and technical personnel for joint venture producing over 36,000 automotive electro-mechanical sun visors and composite headliners per day in Marlette, MI.
• Conceptualized and implemented additional business, increasing sales by $14 million through cost justifying, designing plant layout, pull scheduling and introducing new flexible forming technology.
• Managed 27 major and minor product launches in three years, including supporting foreign launches with cost estimating/tooling.
• Conducting Kaizen COMPASS activities to improve efficiency and create enough floor space to accommodate growth. Complete responsibility for a $3.9 million capital budget.
• Restructured maintenance to a visual TPM planned maintenance system resulting in decreased machine failures, faster repairs, and consistently achieving 95% equipment uptime with expenses below budget..

Stamford, Connecticut, US

• Engineering Manager for an 800-employee business producing more than 96,000 power and manual seats adjusters each month in Elsie, MI.
• Coordinated seven new program introductions with complete project management responsibility for $2.8 million annual capital budget.
• Managed staff utilizing value analysis and computer simulation to switch two assembly lines into flexible work cells, resulting in $990,000/year savings.
• Focused kaizen activities for management peer team to: reduce work process inventory from $763,000 to $311,000 (60%); inventory from $4.9 million to $3.4 million (30% reduction); and production output was increased.
• Reorganized personnel with annual savings of $740,000/year on sales of $120 million. Acting Plant Manager as required and installed process fail-safes, reducing customer returns from 1,263 to 69 PPM, considered "world.

Irvine, California, US

• Promoted from Industrial & Facilities Specialist in first North American Mazda plant in Detroit, MI, producting over 1,000 Ford Probe and Mazda MX-6 automobiles per day.
• Coordinated 1992, 1994 new model for facilities, equipment, and directly managed tooling tryout, including overseeing pilot, quality and productivity of 427 new dies designed and built in Japan.
• Combined kaizen skills and press/automation knowledge to lead team in Die Change Challenge competition over four years, achieving internationally acclaimed Overall Winner ‘90 and Best in North America ‘92. [ref..

Detroit, Michigan, US

• Industrial Engineer and cooperative education student in highly touted undergraduate program and assigned to 13 departments.
• Published thesis entitled "Improving Press Uptime," reducing changeover times from 7 hours to less than 3 hours through variation reduction, workplace organization, SMED and visual.

Master Of Science - Manufacturing Engineering & Management, Mfg. Eng. & Mfg. Mgt.

Masters Certificate In Applied Project Management, - Program And Project Management

Lean Six Sigma Blackbelt Certification, - The George Group

Bachelor Of Science - Industrial Administration, Engineering Mngt.

Uscg Merchant Mariner - Ocean Master Captains License

Education record