Thomas Kosiorek, Mse Email & Phone Number

Troy, Michigan, United States

Farmington Hills, Michigan, United States

Warren, Mi

Managed all new Instrument Panel (IP) for 2020 Buick Enclave for China.• Developed and executed DFMEA project to lead timely completion of action items ahead of critical program sourcing deadline, bringing program ahead 2 months and back on schedule.• Developed program first tactical timeline for IP components for DFM, Mold Flow, OKTT, TKO, First Shots, & Testing to directly manage timely completion / promote early issue awareness.• Created detailed documentation per component ensuring accurate communication of design, mass, and cost details with commodity leads during component reconciliation for production.• Strong focus on China customer requirements through creation of best practices, tracking Compass Warranty data, and direct work with Application Engineers in China.• Led redesign of knee bolster to integrate switch bezel, reduce part complexity, reduce design variation, and increase impact strength >10% to prevent part detachment during impact.• Co-led design of IP Lower Mid Closeout to Kickstand to meet studio Vice President late part breakup request and was able to ensure no fastener strategy impact and no timing impact.• Led Glove Box and Knee Bolster deletion of independent brackets by integrating structure in die draw reducing complexity and improving performance to exceed rigidity & GD&T targets.• Led weekly Product Development Team (PDT) design reviews for IP Upper/Lower to maintain cost and obtained mass 0.6kg below target.• Worked with architectural programs to introduce lessons learned guiding common solutions.• Collaborated with process owners to fix process issues with China only programs.

Warren, Mi

Contract position through RGBSI to manage Instrument Panel (IP) & Floor Console (FC) release.• Led four PDTs globally for IP & FC on the Chevy Volt and China Buick Velite through collaboration with supplier teams, designers, buyers, specification analyst, and Program Manager. • Created & standardized the Continuous Improvement PDT Workbook as a single source of information for BOM alignment, Design/Manufacturing Requirements, Build Options, Current Issues, Change Requests, and Decision Notices for optimal program team guidance.• Wrote Engineering Work Orders (EWOs) to manage the BOM content for Pre-Production Builds, Non- Saleable Builds, Saleable Builds, and Start of Regular Production for MY17-20. • Led design studies for packaging future program content and interfacing with Electrical DRE, HVAC DRE, Switch DRE, and Structure DRE ensuring proper interfaces & packaging constraints.

Auburn Hills, Mi

Developed financial metrics, program timing, and overall program guidance.• Led ER&D analysis for Engineering and Powertrain organizations for NAFTA and EMEA teams to ensure program met financial metrics and maintained positive NPV.• Led multiple PreSpend rollups for Engineering and Powertrain organizations for NAFTA team during design phase leading to full program approval ahead of program deadline.• Monitored Total Program Checkbook ensuring the design, engineering, and supplier teams stayed within spending limits and promptly reported adjustments if overages occurred.• Developed and managed new Change Management and Quality processes between Fiat, Chrysler LLC, and Mazda Motor Corp. by merging processes into one accepted process.• Led senior management financial reviews ensuring financial impacts were promptly resolved.

Auburn Hills, Mi

Led body / exterior systems integration and virtual validation process and tool development.• Executed customer focused functional objectives consistent with strategic targets and brand identity to influence designs and source packages through regular team reviews of requirements and validation plans.• Created standard sort criteria mirroring DFMEA risk priority number methodology to bring focus to functional objectives requiring virtual tool development and provide customer importance guidance to each objective.• Aligned virtual tool set and physical-to-virtual correlation criteria to objectives for each attribute team.

Auburn Hills, Mi

Contract through Synergia Automotive LLC responsible for managing body / exterior systems integration.• Generated a DFSS House of Quality matrix to define the relationships between customer desires and product capabilities to allow generation of engineering requirements to meet the Voice of the Customer.• Created a comprehensive list of functional objectives through collaborative team work for body and exterior systems that lead to a standard start template for the vehicle integration organization.

Warren, Mi

Managed global warranty on automotive instrument panels and floor consoles for 11 programs.• Reduced interior warranty 20% below company targets by leading weekly project reviews with design engineers, suppliers, and manufacturing globally. • Decreased department structural costs by approximately $350K by leading webcam based part reviews in place of international shipping and traveling, while maintaining effective learning of part failure modes.• Executed sufficiency plans ensuring cost of re-design and tooling did not exceed warranty cost savings.

Warren, Mi

Executed subsystem validation and test procedures on automotive closures for 15 programs.• Reduced testing time by 2-6 weeks and costs by roughly 10% through developing enhanced testing procedures, part procurement forms and testing checklists. • Effectively trained team members on Federal Motor Vehicle Safety Standards ( FMVSS ) requirements and documentation changes as well as on a new global document and data management system. • Improved reliability and durability to best in segment targets for the Chevrolet Malibu by applying Design for Six Sigma, Design Review Based on Failure Modes / Test Results, and Weibull Analysis strategies.

Warren, Mi

Managed company’s test labs on Sundays as a part of a cost savings initiative. • Minimized testing downtime from a potential of 72 hours to 1-2 hours on average through supervision of two technicians, two union build members, and one electrician on weekends.• Aided in the management of a team project for the corporation saving $3-4 million annually using offset employee schedules to eliminate overtime pay for testing facilities.

Bachelor Of Science In Engineering, Mechanical Engineering

Activities and Societies: Member of Golden Key International Honor Society Member of Tau Beta Pi National Engineering Honor.

Masters Of Science In Engineering, Mechanical Engineering

Activities and Societies: Member of Oakland University Alumni Association Member of Tau Beta Pi National Engineering Honor.