Sean Fleming

Sean Fleming Email and Phone Number

VP - Engineering - Systems @ Metalsa | Innovation Mgt
Sean Fleming's Location
Abingdon, Virginia, United States, United States
About Sean Fleming

With over 28 years of experience in the automotive industry, I am a global technology leader with expertise in frame design and development, systems engineering process, and product innovation. As the VP - Engineering - Systems at Metalsa, I lead a cross-functional team to manage the requirements, design, and development of a Medium Duty Battery Electric Skateboard that integrates frame, brake, steering, suspension, and axle systems with powertrain and body. My mission is to deliver high-quality, cost-effective, and sustainable solutions that meet the needs and expectations of our customers and stakeholders.In my previous role as the Vice President of Technology at Metalsa, I developed and implemented a global technology strategy that spanned four regions: Brazil, India, Thailand, and North America. I successfully converted customers to more advanced and efficient materials and processes, resulting in significant improvements in strength, durability, profitability, and sales. I also led the development of several innovative products, such as the 100% aluminum frame assembly, the Toolless crossmember, the Next Generation Frame, and the new heat treatment process, that achieved substantial weight reduction, consolidation, patent awards, and cost savings. I leveraged my skills in global cross-functional team leadership, product development and design, and engineering mechanics to drive excellence and innovation in the frame market.

Sean Fleming's Current Company Details

VP - Engineering - Systems @ Metalsa | Innovation Mgt
Sean Fleming Work Experience Details
  • Metalsa
    Vp - Engineering - Systems
    Metalsa Apr 2020 - Dec 2023
    Virginia, United States
    Created Systems Engineering group to manage requirements (V-process) to facilitate the design & development of a Medium Duty Battery Electric Skateboard consisting of frame, brake, steering, suspension and axle systems that would be integrated to powertrain and body.
  • Metalsa
    Vice President Of Technology
    Metalsa Mar 2010 - Feb 2020
    Roanoke, Virginia, United States
    Promoted to develop global technology team (Brazil, India, Thailand and NA) - focus areas:BRAZIL - Converted customer from HSLA steel siderails to Heat-Treat that resulted in 50% greater strength & durability.INDIA - Converted customer from contour rail to straight for highest volume product - resulted in 10x increase in annual sales, improved profitability of plant and significant cost reduction to customerTHAILAND - Developed CNC punch press that would produce "European" quality rails with "Low Cost Asian" capex - approx 1/2 capital cost w/ equivalent quality & productivityNORTH AMERICA - 1)Developed 100% aluminum frame assy w/major OEM and DoE that resulted in 46% weight reduction and provide equal stiffness and performance.2) Developed green, scalable Heat-Treat line for custom application and customer & countries with lower volumes3) Developed revolutionary modular chassis structure w/major OEM resulting in benchmark ride & handling - that resulted in 20% weight reduction and consolidated components to reduce cost by 15%.
  • Metalsa
    Director Of Product Development
    Metalsa Aug 2002 - Aug 2010
    Roanoke, Virginia, United States
    Lead and implemented global technology strategy, some key accomplishments included:1) developed Toolless crossmember - resulted in 15-30% price reduction and eliminated need for tooling/capex - for 2 customers accounted for approx. 15MD savings over 2 years2) Developed Next Generation Frame (Z-Frame) that resulted in 10% Wt Reduction, 25% consolidation in fasteners, 2 patent awards and accounts for 5-10MD annual savings to key customer.3) Developed new HT process to increase strength from 110KSI to 120Ksi - ultimately to 140 and 160ksi - resulting in 15% wt reduction to customer and 2.5-3x profit for Metalsa. (WTP pricing)4) Developed comprehensive 3 day course on "Fundamentals of Metal Fatigue" for both internal and external customers. (note: course became one OEM handbook on Fatigue)
  • Metalsa
    Resident Engineer & Account Manager
    Metalsa Jan 2000 - Aug 2002
    Seattle, Washington, United States
    Served as Resident Engineer & Account Manager for Major Commercial Vehicle OEM on West CoastWas direct contact with Chief and Assist Chief Engineers on all issues related to chassis and structure.Also handled all plant related issues related to frame structures.Was also the account manager for commercial issues between OEM and Metalsa.
  • Metalsa
    Project Engineering Leader
    Metalsa Apr 1999 - Jan 2000
    Milwaukee, Wisconsin, United States
    Focus to id cost savings and revenue generating opportunities - key accomplishments:1) Multipiece siderail - reduce wt 30% and cost savings of 15% - approx. 6MD savings /yr for customer2) Added punched holes to siderail to eliminate stud-welding - OEM credited $800KD3) Reduced double sided wield to single sided weld - met durability targets and reduced yearly cost appox. 500KD.
  • A. O. Smith Corporation
    Product Development Engineer
    A. O. Smith Corporation Jul 1995 - Apr 1999
    Milwaukee, Wisconsin, United States
    Lead Test/Development Engineer for Major NA OEM Utility Vehicle - Frame & Chassis - key activities:1) reduce road load data to test / drive files for accelerated testing2) actively monitor all testing - frame level and bench3) direct contact w/OEM program manager and release engineer4) work with FEA and Design engineers on any durability issues and ensure structure met 150%PG damage with no parent metal cracks and no weld cracks beyond 12mm.

Sean Fleming Education Details

Frequently Asked Questions about Sean Fleming

What is Sean Fleming's role at the current company?

Sean Fleming's current role is VP - Engineering - Systems @ Metalsa | Innovation Mgt.

What schools did Sean Fleming attend?

Sean Fleming attended Northwestern University, Michigan State University, Saginaw Valley State University.

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