Thomas Benaglio
Sr. Manufacturing Engineering - Program Manager at FTE Performance Consulting, Inc.- Claim this Profile
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Bio
Credentials
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NFPA Member
-Apr, 2014- Sep, 2024 -
AIAM Member
Aerospace Industry Association of Michigan (AIAM) -
SAE Member
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SME Member
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Experience
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FTE Performance Consulting, Inc.
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United States
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Business Consulting and Services
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1 - 100 Employee
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Sr. Manufacturing Engineering - Program Manager
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Aug 2021 - Present
Instrumental in implementing lean manufacturing principals to increase productivity. Increased productivity/revenue by $18 mil in one year (company A). Increased productivity by 20% (company B). Designed, developed, and installed new process for EV buses at the plant from design to production run-off. All systems custom designed and built. Instrumental in implementing lean manufacturing principals to increase productivity. Increased productivity/revenue by $18 mil in one year (company A). Increased productivity by 20% (company B). Designed, developed, and installed new process for EV buses at the plant from design to production run-off. All systems custom designed and built.
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Hines Industries, Inc.
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United States
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Machinery Manufacturing
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1 - 100 Employee
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Engineering Manager, Sales Manager, Service Manager, Manufacturing Manager - Integrator - COO
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Nov 2018 - Aug 2022
Manage business with sales, service, engineering, and manufacturing. Work directly with CEO determining business direction. Manage business with sales, service, engineering, and manufacturing. Work directly with CEO determining business direction.
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IMPCO Automotive
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United States
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Motor Vehicle Manufacturing
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Engineering Manager / Program Manager
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Feb 2012 - Aug 2022
Design and development of alternative fuel systems for vehicles and light/medium duty trucks. Lead team (direct reports) consisting of product engineers, program managers, designers, manufacturing engineers, and technicians designing and developing thru release of alternative fuel systems. Design and development of alternative fuel systems for vehicles and light/medium duty trucks. Lead team (direct reports) consisting of product engineers, program managers, designers, manufacturing engineers, and technicians designing and developing thru release of alternative fuel systems.
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Eberspächer Group
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Germany
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Motor Vehicle Manufacturing
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700 & Above Employee
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Launch Manager
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Jan 2017 - Oct 2018
Managed 7-10 launch programs per year. Coordinated customer meetings, internal meetings, lead engineer in process improvement and efficiency improvement. Scrap reduction, lean manufacturing. Managed 7-10 launch programs per year. Coordinated customer meetings, internal meetings, lead engineer in process improvement and efficiency improvement. Scrap reduction, lean manufacturing.
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Program Engineering Manager / Advanced Manufacturing Engineer / Consultant
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2010 - 2012
Manage launch of new program for international project (Asia). Design and develop manufacturing, fabrication and assembly processes to produce the Track Type Tractors in a green facility. Direct and coordinate all departments to follow established timelines. Direct team of engineers to meet objectives. • Managed/coordinate quotation process, supplier selection, and process development. • Instrumental in creating project timelines/goals and managing the team to meet these goals. • Develop lean manufacturing and fabrication processes and overall plant layout
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Dowding Industries Inc.
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United States
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Industrial Machinery Manufacturing
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1 - 100 Employee
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Manufacturing Engineering Manager
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2008 - 2010
Manage fabrication department including laser cutting, forming, friction welding, MIG and TIG welding including robotic welding and robotic programming (Kuka, Fanuc, Lincoln Electric). • Instrumental in reducing indirect labor costs (from 70 % indirect to 20%), reducing plant wide scrap, and increasing production efficiencies through lean manufacturing and production layout. • Design, develop, and implement new manufacturing process for new customer programs including robotic welding systems. Modification of existing processes and procedures. • Manage / coordinate engineering quotation process, forecast planning, quality control and continuous improvement projects. • Instrumental in managing new programs from design to customer approval in their plants.
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Program Director , Sales and Marketing Liason
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2003 - 2008
Engineering coordination for various innovative products for automotive, industrial, military and medical industries. Create new strategies to increase sales revenues and expand market base. Develop sales / product customer presentations. Designed and developed manufacturing processes for new performance products for powertrain systems utilizing DFM. Managed/coordinated manufacturing sites in Europe for procurement of domestic products utilizing lean manufacturing. • Solely instrumental in increased sales by 85% with an additional 200% pending sales. • Consulting for manufacturing process improvements including lean manufacturing, project manager. • Instrumental in obtaining new business at Honda NA, John Deere, Harley-Davidson, Oshkosh, GM, Daimler-Chrysler, Ford, Roush, military and many other tier one customers. • Instrumental in modifying processes for European manufacturing plant to improve productivity.
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Grob Systems, Inc.
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United States
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Machinery Manufacturing
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1 - 100 Employee
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Program Manager, Sales and Marketing Manager
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1998 - 2003
Engineering coordination for various innovative products for automotive, industrial, military and medical industries. Create new strategies to increase sales revenues and expand market base. Develop sales / product customer presentations. Designed and developed manufacturing processes for new performance products for powertrain systems utilizing DFM. Managed/coordinated manufacturing sites in Europe for procurement of domestic products utilizing lean manufacturing. • Solely instrumental in increased sales by 85% with an additional 200% pending sales. • Consulting for manufacturing process improvements including lean manufacturing, project manager. • Instrumental in obtaining new business at Honda NA, John Deere, Harley-Davidson, Oshkosh, GM, Daimler-Chrysler, Ford, Roush, military and many other tier one customers. • Instrumental in modifying processes for European manufacturing plant to improve productivity.
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Plastic Omnium
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France
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Motor Vehicle Manufacturing
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700 & Above Employee
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Engineering Manager of North American Operations
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1997 - 1998
Managed all customer-based operations related to fuel system applications engineering, including plastic injection, insert, and blow molding of fuel system components (GM, Ford, Honda). Worked closely with design engineers to identify particular component needs and developed effective product solutions to meet required current/future government specifications. Components include extruded fuel lines, fuel tanks, in-tank fuel pump components, fuel pump modules, injectors, regulators, integrated fuel manifolds, etc. • Instrumental in developing/implementing new technical facility including test lab and CAD. • Played a key role in negotiating a joint venture with Tier 1 supplier to facilitate future business. • Managed design engineers and CAD designers to create state of the art fuel system manufacturing processes for both gas and alternative fuels.
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Bosch North America
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United States
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Account Manager of Technical Sales Engineering
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1991 - 1997
Researched/analyzed market trends, evaluated target markets during new product development, and assisted with product and business development activities for Tier 1 Automotive supplier of engine and fuel management, HVAC, and ABS brake systems. • Responsible for managing $123 million in annual sales for various programs. • Administered sales/marketing budgets and supervised 8 designers, 6 product engineers, and 5 sales engineers. Supervised and motivated sales team to meet/exceed target sales goals. • Re-structured the organization into a matrix structure including European operations.
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Engineering Design and Development Manager
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1988 - 1991
Facilitated new product design/development and collaborated with Project Engineers to prepare proposals for long-term engineering contracts, create project budgets and product delivery schedules. Managed and trained 6 application engineers and 10 designers. Conducted customer meetings and made presentations at all customers. Team leader in lean manufacturing in SC plant for high volume injector and fuel pump production. Alternative fuels coordinator between all plants.• Designed and started production of first fuel pump module for domestic application. • Hold patent for specific liquid discriminating valve involving advanced fluid dynamics. • Designed high performance fuel systems for automotive industry.• Instrumental in increasing production output by 25% and reducing scrap by 15% of injector lines.
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General Motors
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United States
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Motor Vehicle Manufacturing
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700 & Above Employee
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Advanced Powertrain Engineering Staff
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1980 - 1988
Instrumental in developing future engine designs and manufacturing sites. Worked with engineering staff at the University of Illinois to develop computer simulation of machining processes. Developed and implemented CAT scan machine for process control. Sr. Production/Product Engineering - Designed the initial manufacturing processes of the Quad 4 engine components including blocks, heads, cams, cranks, rods, and pistons. Produced mechanical designs/drawings, communicated project details to production teams, and resolved various production and engineering problems.
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Education
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1976 - 1979
Michigan Technological University
Bachelor’s Degree, Mechanical Engineering -
Seaholm
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