Experience

Toyota Boshoku America

• United States
• Motor Vehicle Manufacturing
• 700 & Above Employee

• Manager - Strategic Projects & New Model Launch

  • Jan 2020 - Present

• Engineering & Maintenance Manager

  • May 2014 - Jan 2020

• Technical Launch Manager - Engineering

  • Mar 2010 - May 2014

   Responsible for all technical aspects of the $13.8M 760A program; including MvB studies, Cost Models, Process plans, capital equipment & tooling specifications, design for manufacturability studies & capital budget. Was responsible for all technical aspects of the $12.6M 420A program; including approval of process plans & capital equipment/ tooling specifications. Providing oversight on capital budget proposals and providing vital feedback to our design group on design for manufacturability concerns.  Responsible for ensuring the 420A launch schedule was met with respect to installation/commissioning and pre-production validation testing.  Was responsible for ensuring TBCA was capable of meeting a late 50% volume increase issued by our customer. TBCA was able to hit capacity target with <$1M in capital investment. This work allowed TBCA to post a $7.3M cost avoidance (plan vs actual). Was charged with reducing one shift from the 420A weld line with a budget of less than $125k. Target was achieved within 3 months with a total cost of $117k. This allowed TBCA to post an additional labor savings of $832k/yr. Part of the 420A launch team that has the distinction of being the first of Toyota's NA interiors companies to officially pass the HVPT milestone on its first attempt for multiple commodities (4 commodities: Carpet/Headliner/Seat Assy & Door Ass'y) Was responsible for several VA/VE projects that resulted in more than $910k/yr in cost benefit for TBCA.

• Assistant Manager - Process Engineering

  • Mar 2007 - Mar 2010

   Responsible for all maintenance and engineering related responsibilities for TBCA's seat assembly line, multiple weld lines & its pipe bending line. Led the Kaizen department which was responsible for over 42 process reductions over my tenure, including a TBCA-E record 28 in 2010.  Reduced weld repair rate from 5.3 to 1.2% of total welds through process optimization and enhanced equipment selection. Was charged with planning and executing the smooth transition of capital equipment from a financially troubled vendor to TBCA. This time sensitive project was completed in less than 2 weeks & without any customer interruption.  Was responsible for several VA/VE projects that continue to generate revenue. To date these projects have resulted in more than $7.2M in cost benefit for TBCA.



ABM Tool & Die

• Robotic Welding & Automated Manufacturing Manager

  • Aug 2006 - Mar 2007

   Reporting directly to the owner and CEO, I managed all aspects of the Robotic Welding & Automated Manufacturing Department. This included scheduling all production activities to ensure 100% on time shipment against customer releases.  Had direct control over a labor force of 62 employees including production workers and weld technicians.  Handled all related customer complaints and oversaw their resolution in a timely fashion.  Charged with reducing overtime and increasing the department’s overall profitability.  Developed and implemented a KPI monitoring system, which was successfully, adopted company wide.  Chaired the company’s Continuous Improvement Committee meetings.  Maintained the duties of “Welding and Robotics Engineer” outlined below.

• Welding Engineer

  • Oct 2004 - Aug 2006

   Hired to head-up A.B.M.’s newly formed welding department.  Responsible for preparing all newly acquired equipment for PPAP as well as streamlining the processes prior to S.O.P.  Charged with developing and implementing the policies and procedures that governed ABM's welding department.  Responsible for providing the sales Director with cost estimates/ for use in quoting new business as well as providing development costs for pre-production and prototype phases of new contracts. Performed design reviews on new equipment concepts and provided direction to the equipment integrators; ensuring A.B.M.’s concerns were addressed prior to delivery of new equipment.  Work closely with the Quality Engineers to complete PFMEAs for all new processes.  Worked in collaboration with outside contractors during installations.  Produced Equipment Readiness Reports to apprise the Sr. Management group of the status of all automated equipment in the facility.  Led R & D activities; with respect to new processes and procedures with a focus on innovative technologies. Member of the company’s APQP team.  Integral part of the company’s Continuous Improvement Team.  Facilitated employee training; providing employees with welding, robotics, PLC and maintenance training.