Mike Bonk Email & Phone Number

Livonia, Mi

• Created Corporate process for DFMEA, including templates and special characteristics • Led root cause analysis teams for multiple gear noise, vent leak, clutch disc , NVH and bearing design and warranty issues leading to design corrections and improvements. • Certifications: AIAG internal auditor training/cert, ISO 14001 certification and training • Training received: International Durability and Reliability seminar. ASQ Learning Institute Reliability engineering… Show more • Created Corporate process for DFMEA, including templates and special characteristics • Led root cause analysis teams for multiple gear noise, vent leak, clutch disc , NVH and bearing design and warranty issues leading to design corrections and improvements. • Certifications: AIAG internal auditor training/cert, ISO 14001 certification and training • Training received: International Durability and Reliability seminar. ASQ Learning Institute Reliability engineering training, AIAG & VDA Design FMEA Training by AIAG. • Provided green and yellow belt training and certification support for 20+ employees • Created reliability plans for multiple new project designs to meet customer requirements including creating test plans to validate and meet requirements. • Lead multiple DFMEA teams to create useful and functional documents including customer sign offs and review yearly • PFMEA hand off and support of identified special characteristics from design side to manufacturing partners • Data analysis and approval of supplier validation testing and plans used for process and design changes of supplied components • Create and provide internal Engineering department training for the following topics: Special characteristics, DFMEA, Reliability analysis and design, Design for X (manufacturing and assembly), Pugh matrix and boundary diagram creation and usage and (D.O.E.) Design of Experiments creation and usage • Warranty analysis • Performed analysis of test facilities usage in house and created an automated method of tracking metrics and reporting • Perform multiple internal ISO audits yearly Show less

• Completed and received Six Sigma Black Belt certification. Train green belts. Organized team training course for green belts. • Closed 58 CPI projects with a total warranty impact of over $29,000,000 between 2010-16. • Initiated reevaluation of service plan resulting in $3,000,000 cost avoidance and drove wheel bearing process, instead of design improvement solution, avoiding $2,800,000 in cost and $80 per machine to customer cost in 2015.• Drove design direction on top product… Show more • Completed and received Six Sigma Black Belt certification. Train green belts. Organized team training course for green belts. • Closed 58 CPI projects with a total warranty impact of over $29,000,000 between 2010-16. • Initiated reevaluation of service plan resulting in $3,000,000 cost avoidance and drove wheel bearing process, instead of design improvement solution, avoiding $2,800,000 in cost and $80 per machine to customer cost in 2015.• Drove design direction on top product group project including the development of a $4,000,000 cost avoidance in 2013.• Review and analyze warranty and failure rate data to find issues that need to be addressed. • Create and lead teams with support from necessary groups to determine root cause, create a interim and permanent corrective action and implement to production and field. Teams typically include design and manufacturing engineering, product support, subject matter experts (heat treat, bearings, materials), supplier quality.• Analyze failure parts and reports. Applied failure analysis.• Root cause determination; Ishikawa/fishbone diagrams, Is/Is not charts, Global 8D, 5 whys.• Root cause validation; Lab and analytical validation, design of experiments.• Update process and design FMEA’s to capture lessons learned.• Implementation of interim and permanent corrective action.• Guide development of field service plan.• Work with suppliers to correct quality issues.• Contact and support supplier warranty cost recovery efforts.• Report out to upper management and machine group managers with updates.• Participate in global dealer conferences in support of projects.• Track closed projects effectiveness.• Lead recruiter for engineering at Michigan State University. Coordinate on-campus recruiting; perform targeted selection interviews for full time and intern hiring and responsible for team staying on budget. Show less

• Team lead for lower powertrain analysis team. Schedule and assign work to team members.• Histogram and duty cycle creation and analysis for lower powertrain design.• Perform lower powertrain bearing analysis for large scale differential applications.• Perform specific mine site analysis to help sell Large Mining Trucks• Automated time consuming “non-core” analyses steps to allow lower cost outsourcing of specific mine site analyses• Key contact and owner of machine… Show more • Team lead for lower powertrain analysis team. Schedule and assign work to team members.• Histogram and duty cycle creation and analysis for lower powertrain design.• Perform lower powertrain bearing analysis for large scale differential applications.• Perform specific mine site analysis to help sell Large Mining Trucks• Automated time consuming “non-core” analyses steps to allow lower cost outsourcing of specific mine site analyses• Key contact and owner of machine performance data that established the design, form and fit of the lower powertrain system. Modification and upkeep of multiple machine family performance data. Show less

• Received Certificate of Merit for Extraordinary Accomplishments and Leadership, Jan. 6, 2000 for helping to create a global technical and commercial bearing sourcing plan.• Researched, guided design, tested and validated “fuel efficient” tapered roller bearings for rear axle programs.• Root cause and failure analysis of test and field failures, including 8D and technical write ups of findings.• Work with production facility to ensure best design for assembly and to correct quality… Show more • Received Certificate of Merit for Extraordinary Accomplishments and Leadership, Jan. 6, 2000 for helping to create a global technical and commercial bearing sourcing plan.• Researched, guided design, tested and validated “fuel efficient” tapered roller bearings for rear axle programs.• Root cause and failure analysis of test and field failures, including 8D and technical write ups of findings.• Work with production facility to ensure best design for assembly and to correct quality problems.• Write bearing test specifications and procedures; rear axle key life test, updated majestic wheel bearing test.• Prepare and teach bearing design and application class in internal design institute.• Researched, developed and tested cost reduction opportunities in bearings; induction hardening, modified heat treatment. Potential $1 million cost reduction.• Manage and oversee multiple departments to guide product design, development and release. Departments include; Computer Aided Design, Computer Aided Engineering, Finite Element Analysis, testing labs, axle build up area, machine shop, outside suppliers and prototype shops.• Continued training and research on latest bearing industry technologies to keep Ford designs on the leading edge. Show less

• Received Certificate of Merit for Extraordinary Accomplishments and Leadership, Jan. 6, 2000 for helping to create a global technical and commercial bearing sourcing plan.• Researched, guided design, tested and validated “fuel efficient” tapered roller bearings for rear axle programs.• Root cause and failure analysis of test and field failures, including 8D and technical write ups of findings.• Work with production facility to ensure best design for assembly and to correct quality… Show more • Received Certificate of Merit for Extraordinary Accomplishments and Leadership, Jan. 6, 2000 for helping to create a global technical and commercial bearing sourcing plan.• Researched, guided design, tested and validated “fuel efficient” tapered roller bearings for rear axle programs.• Root cause and failure analysis of test and field failures, including 8D and technical write ups of findings.• Work with production facility to ensure best design for assembly and to correct quality problems.• Write bearing test specifications and procedures; rear axle key life test, updated majestic wheel bearing test.• Prepare and teach bearing design and application class in internal design institute.• Researched, developed and tested cost reduction opportunities in bearings; induction hardening, modified heat treatment. Potential $1 million cost reduction.• Manage and oversee multiple departments to guide product design, development and release. Departments include; Computer Aided Design, Computer Aided Engineering, Finite Element Analysis, testing labs, axle build up area, machine shop, outside suppliers and prototype shops.• Continued training and research on latest bearing industry technologies to keep Ford designs on the leading edge. Show less

• Received Superior Team Member Ranking in recognition of correcting multiple customer quality issues and covering one major automotive customer without sales department representative for most of the year.• Coordinate and oversee bearing application projects from inception to completion with job tasks including; calculate and recommend engineering solutions to customers, make engineering presentations, perform failure analyses and write technical reports for customers.• Work directly… Show more • Received Superior Team Member Ranking in recognition of correcting multiple customer quality issues and covering one major automotive customer without sales department representative for most of the year.• Coordinate and oversee bearing application projects from inception to completion with job tasks including; calculate and recommend engineering solutions to customers, make engineering presentations, perform failure analyses and write technical reports for customers.• Work directly with manufacturing, sales, marketing and design departments.• Responsible for General Motors and Daimler Chrysler engineering accounts• Training in Japanese business culture including 2.5 weeks of training in Japan. Show less

• Received a letter of commendation from Ford SVO for work done on dynamometer, calibration and manifold design for the 4.6L 2V mustang bolt on supercharger package.• Supervise and direct all aspects of engine and component design projects including; sales, design, build, test and development. This involved providing direction and interaction with the following departments; drafting, machine shop, dynamometer laboratory and engine and vehicle build units.• Scheduling and management of… Show more • Received a letter of commendation from Ford SVO for work done on dynamometer, calibration and manifold design for the 4.6L 2V mustang bolt on supercharger package.• Supervise and direct all aspects of engine and component design projects including; sales, design, build, test and development. This involved providing direction and interaction with the following departments; drafting, machine shop, dynamometer laboratory and engine and vehicle build units.• Scheduling and management of specific dynamometer test cells and company resources.• Design and supervise building of stand alone test fixtures for component testing.• Root cause failure analysis, data collection and final results write ups for tests run.• Organize meetings with customers to sell testing and design services, discuss customer needs and report out test and design results.• Create quotations for design and test services.• Contract outside sources for project needs. Show less

• Letter of commendation from Tenneco/Monroe Auto Equipment for working through Christmas holiday break to build and complete a modified suspension Ford Explorer which eventually won a long term contract for production.• Supervise and direct all aspects of engine and component design projects including; sales, design, build, test and development. This involved providing direction and interaction with the following departments; drafting, machine shop, dynamometer laboratory and engine and… Show more • Letter of commendation from Tenneco/Monroe Auto Equipment for working through Christmas holiday break to build and complete a modified suspension Ford Explorer which eventually won a long term contract for production.• Supervise and direct all aspects of engine and component design projects including; sales, design, build, test and development. This involved providing direction and interaction with the following departments; drafting, machine shop, dynamometer laboratory and engine and vehicle build units.• Scheduling and management of specific dynamometer test cells and company resources.• Design and supervise building of stand alone test fixtures for component testing.• Root cause failure analysis, data collection and final results write ups for tests run.• Organize meetings with customers to sell testing and design services, discuss customer needs and report out test and design results.• Contract outside sources for project needs. Show less

Mpd, Masters Of Product Development

Bs, Physics

Education record