1. Tied
vehicle GM Prototype BOM to Raw Material needs and Production BOM. Resulted in first ever prototype vehicle in
new color without timing delays.
2. Devised
new production scheduling system and structure for Budd Cobourg Plant.
3. Devised
new inventory tracking system for Budd Cobourg Plant.
4. Contributed
to the formation of a GM Central Advanced Purchasing Process. Was lone Engineering representative.
5. Devised
JIT system for multiple color painted parts.
1. Wrote
QS9000 work instructions for Budd Program Managers and integrated into Budd
system.
2. Worked
with GM Strategic Bill of Material Team to have GM operating system meet
ISO-9000 requirements. This included
work instruction, process flow, configuration management and tools needed.
3. Helped
devise GM Central Engineering Centers structure and implemented Interior &
Exterior Centers. Participated in
hiring.
4. Wrote
Program Management Manual and Operating System Outline for Budd.
1. Helped
institute Common Operating Environment at GM, C.O.e..
2. Worked
with Divisional Design Chiefs to define standard Design workstation
requirements.
3. Catalyzed
Alias & Wavefront merger. Drove 3D
high resolution graphic software development at GM.
4. Instituted
virtual reality into the market and design research areas of GM.
5. Devised
database system to integrate raw material development , purchasing contracts
and build schedules using “database warehousing” technology.
1. Changed
the GM Vehicle Development Process to reduce cycle time by 20 months.
2. Drove
the use of Subsystem Technical Specifications in part development at GM.
3. Eliminated
retrofitting GM prototype vehicles for new colors by process and information
system integration.
4. Formulated,
with GM Design Staff, a new Color & Appearance Development Process that
eliminated waste in time and materials.
5. Instituted
Statement of Requirements Contracting into raw material buying at GM.
1. Wrote
original Strategic BOM Planning Process and lead subcommittee to final draft.
2. Devised
with BOM Team, standardized bench marking format and lead Subsystem Leadership
Teams in implementing.
3. Identified
investment, by subsystem, for 10 year GM vehicle portfolio.
4. Identified
manpower, by subsystem, for 10 year GM vehicle portfolio.
5. Identified
facilities, by subsystem, for 10 year GM vehicle portfolio.
6. Identified
sales opportunities at GM and Chrysler for Budd Sales Department.
7. Devised
long term plan to change Budd Cobourg Plant product line capabilities.
8. Laid
out Business Planning Process for Budd.
1. Added
conveyor and paint system changes to Budd Cobourg plant.
2. Added
60,000 sq. ft. to Budd North Baltimore to accommodate GMT800 and 560
programs. Also added cure oven,
conveyors and large RIM clamps (8) to meet production needs.
3. Remodeled
building to hold GM Interior & Exterior Centers, including total IT
infrastructure.
4. Acted
as internal consultant for the implementation of $38 million Portfolio
Engineering Center building.
5. Drew
up expansion plans for Cobourg, ONT plant to convert to thermoplastic injection
molding.
1. Worked
with H.B. Fuller, Ferro and Glidden paint companies to devise body color
matching powder paints.
2. Developed
in-mold powder coating system with Nordsen and Ferro.
3. Helped
improve aluminum wheel casting process at Amcast. Greatly improved quality of product and saved their GM contracts.
4. Instituted
RRIM process into Budd North Baltimore plant.
Helped develop processing use for very large parts.
5. Helped
improve SMC molding processes at Budd Cobourg plant.
6. Helped
introduce co-injection molding in the electrical switch market and shift lever
market.
7. Installed
new paint line and process at Fisher Guide - Trenton Plant for W & L car
zinc die cast door handles.
8. Helped
improve many injection molded parts for production.
9. Implemented
PFMEA, Operator Instructions and Control Plans
10. Instituted
new production scheduling system at Cobourg Plant.
11. Helped
reduce the number of hits and dies for body stampings.
1. Re-timed
Budd Cobourg plant, while introducing FIFO and “kaizen” techniques.
2. Re-timed
Budd North Baltimore plant to optimize for introduction of GMT800 RRIM parts
and GMT560 front end systems.
3. Worked
on team to introduce modularity into GM plants.
4. Worked
with GM Manufacturing Center to standardize many in-plant equipment to reduce
capital costs and enhance inter-plant product changeability.
5. Established
good working relationship with Cobourg Union.
1. Facilitated
several Color & Appearance Clinics to establish “Voice of the Customer”.
2. Conducted
several technology Benchmarking studies with Mona Lisa group to identify
“customer satisfiers”.
3. Conducted
Mass Savings Seminar for GM executives.
4. Wrote
a presentation, “Color in Marketing”, depicting the importance of color
technology in the expansion of the automotive industry. Presented to the Paint Manufacturers’ of
America.
5. Worked
with GM Division General Managers to define product intangibles.
6. Instituted
Virtual Reality into the market and design research areas of GM.
7. Wrote
marketing plan for Budd.
1. Devised
a sales approach using an internet website to sell vehicles. “Build your own car” concept now in
use. Devised “alternative, or virtual,
dealer” concept. Step towards “manufacture on demand.”
2. Lead
all Budd quoting teams for GM and Chrysler business.
3. Identified
sales opportunities at GM and Chrysler for Budd Sales Department.
4. Promoted
a consultative sales approach.
1. Represented
GM to the Paint Manufacturers’ of America.
Presented, “Color in Marketing”, depicting the importance of color
technology in the expansion of the automotive industry.
2. Worked
with an American & British trade magazine.
They wrote “A Colorful Future for Aluminum Wheels” about my introduction
of new powder paint technology into the wheel industry and its profound
effect. For worldwide distribution.
1. Participated
in over 45 GM vehicle launches.
2. Ran
GM Midsize Car Division Appearance Engineering Department.
3. Released
all appearance parts of all GM Midsize Car Division vehicles.
4. Helped
devise Product Development Process for the Budd Company.
5. Helped
institute ISO & QS-9000 certification.
6. Implemented
the use of DFMEA, FEA and Mold flow analysis.
1. Worked
with Divisional Design Chiefs to define standard design workstation requirements.
2. Was
catalyst for Alias & Wavefront merger.
Drove 3D high resolution graphic software development at GM.
3. Instituted
Virtual Reality into the market and design research areas of GM.
4. Instituted
a math template priority system to quickly surface decisions during design
theme development at GM
5. Instituted
a “design review room” concept that used large scale monitors to show designs
straight off the workstation.
1. Instituted
Color & Appearance Material tolerencing to standardize appearance
approvals.
2. Devised
standardized Color & Appearance Standards
3. Involved
in many part approvals (PPAP).
4. Started
Continuous Improvement Plans at Budd Cobourg plant.
5. Knowledgeable
in QS 9000 / APQP / DFMEA / PFMEA / Control Plans
6. Introduced
common Prototype / Production gage concept to Budd. Use CMM fixture during prototype, then convert to gage for
production.
7. Instituted
Six Sigma defect tracking at Cobourg Plant.
1. Introduced
detailed Piece Price Breakdown costing to Budd.
2. Lead
GM efforts at Investment Benchmarking / Tracking for body subsystems.
1. Devised
new Color & Appearance Department budget format to more accurately control
costs. In conjunction with GM Financial.
2. Introduced
product focused Budget Summary Sheets to Budd.
Showed cots of each product made.
Used in later cost savings analysis.
3. Devised
method of identifying subsystem piece and investment costs for strategic
planning and vehicle charter development purposes.
1. Originated
assessing programs as cost centers at Budd.
2. Originated
basing program performance on ROS at Budd.
3. Participated
in assessing GM cash flow using strategic BOM financial planning elements.
1. Developed
numerous paint technologies for GM. Included were soft touch, colored powder,
high resilient paints. Also devised
appearance ELPO based products.
2. Helped
develop numerous plastic technologies at GM.
Included were low density polyethylenes, high crystalline
polypropylenes, TPO’s, ABS’s, vinyls, nylons and polycarbonates.
3. Helped
in the introduction of many non-woven textiles into GM vehicles.
4. Helped
in the introduction of new non-corrosive metals into vehicles.
5. Contributed
to the development of a more accurate accelerated weathering specification and
test method.