Feb 2023 – Present · 3 yrs 3 mos

• Led the implementation of Ford North America's Lean and Six Sigma strategy, driving process efficiencies and promoting a culture of continuous improvement.
• Mentored Plant Leadership, Black Belts, and Green Belts in Lean and Six Sigma methodologies, guiding project teams in the effective use of Six Sigma tools to enhance problem-solving skills, ensure successful project completion, and align with strategic goals and quality standards, thereby fostering operational excellence.
• Developed and taught Six Sigma Black Belt and Green Belt certification classes, preparing participants for industry-recognized certification.

Apr 2022 – Apr 2023 · 1 yr

• Led development initiatives for the powertrain eMotor manufacturing commodities including identifying, defining, and prioritizing manufacturing technology.
• Developed and delivered new manufacturing technologies through ideation, concept generation, and application ready (AR) leading a cross functional team of Ford and external suppliers.
• Applied systems engineering approach with disciplined six sigma methodology and a data driven mindset
• Planned and scheduled installation of prototype factory equipment

Nov 2020 – Apr 2022 · 1 yr 5 mos

• Create proof of concept solutions using analytic software, methods, and technologies to assess their potential impact on processes. Managed the design, creation, and delivery of analytic projects to support global manufacturing processes. Projects developed and managed worth an estimated $2.165 million in business savings per year
• Developed analytic using Alteryx/SQL/Hadoop to alert statistically different amounts of rejects from parallel machines estimated $162,400/year
• Created Birth History analytic using Alteryx/SQL/Hadoop to streamline getting quality data from 5 different sources estimated $384,000/year

Nov 2018 – Nov 2020 · 2 yrs

• 3D printing and 3D scanning lead for Romeo Engine Plant (Stratasys F370, GrabCad, Artech Studio). Through 3D printing / Scanning was able to achieve hard savings of $31,882 and scrap prevention of 1.3 Million dollars by continuously finding potential use cases, printing parts out, and testing them.
• Received Ford Technical Excellence Award: 3D Hand scanning for optimization of Crankshaft forgings
• Broke PV8 Crankshaft bottleneck by optimizing motions of balance machine. Increased station JPH by 3, and improved line JPH of 0.9 JPH for an estimated savings of $158,000.
• Broke Maverick Crankshaft bottleneck by reducing the amount of double corrections by 96%. Increase of 1.45 JPH in station with a line improvement of0.8 JPH for an estimated savings of $97,000.
• Brought FFT Adcole upgrade in for PV8 crank line, tested it out, completed capability, and released to production.
• Secured funding for Drone (DJI Mavic 2 Enterprise) and performed flight missions for plant

Jun 2018 – Nov 2018 · 5 mos

• Improved weekly Final Test stand FTT from 96.89 (Jan 7 – Aug 25), to 98.01 (Aug 26 – Nov 3)
• Assist Maintenance and Production in the troubleshooting and repair of down test equipment. Investigate and implement corrective actions to address top availability issues (I. E. faults and downtime)
• Perform calibration of test stand instrumentation per schedule
• Lead reject resolution in addressing test stand top First Time Through (FTT) concerns using WMA software. Conduct monthly review of all critical test points and monitor stand-to-stand correlation.
• Maintain cycle times on test equipment ensuring stands are running at or below authorized cycle time
• Provide quality analysis and assist garage in determining root cause of returned transmissions, implement corrective actions and document improvements to test equipment.

Jul 2016 – Jun 2018 · 1 yr 11 mos

• Drive continuous improvement in safety, quality and productivity. Pull production data (FIS) and review for abnormalities/opportunities to improve the process.
• Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products
• Support production in the troubleshooting and maintenance of ~ 100 CNC machines.
• Develop action plans as required to investigate and prioritize quality concerns and verify corrective actions on internal processes
• Perform cycle time analysis/investigation to catch/correct cycle time degradation and find cycle time improvements.
• Analyze root causes; engage in mapping and corrective actions
• Drive variability reduction, lean manufacturing initiatives and best practices for operations
• Identify throughput constraints and drive root cause improvements
• Monitor and adjust tool life, work with suppliers to improve current designs or create new designs to improve tool life.

Jan 2016 – Jul 2016 · 6 mos

• Developed Leak and Porosity Specification for Transmission Case and Converter (8F57)
• Developed DFMEA for next generation Hybrid Transmission Case and Converter as well as for 8F57
• Created boundary diagram and SCCAF for Transmission Case and Converter for HF45 and 8F57
• Worked with suppliers to develop transmission structures castability as well as machinability

Jul 2015 – Dec 2015 · 5 mos

• developed cycle time estimations for machining (9FM) to determine number of machines required for new program
• Led capability runs for launch of new department: Tool change study, 30 piece capability, cold start study.
• Created and maintained Launch readiness and control documents for implementation of new program standards

Nov 2014 – Jul 2015 · 8 mos

• Initiated and Lead cross functional team in problem solving low FTT – Over 4 months increased test stand FTT from 89% to 95%
• Responsible for Developing and Maintaining systems which supports the quality operating system (Transmission Case / Converter Machining, Valve Body Machining, Main Control Assembly)
• Lead 8D problem solving activities with suppliers to implement interim and permanent corrective actions to resolve quality issues.
• Accountable for ensuring new/modified dies from suppliers for machining are up to standards in regards to FTT, Porosity, and Quality using PPAP process.

Jul 2014 – Nov 2014 · 4 mos

• Lead Safe exit project to ensure quality of parts received was not compromised as program was coming to an end
• Lead 8D meetings to determine root cause of supplier quality issues and implement permanent corrective action
• Responsible for investigating supplier quality problems, issuing quality rejects, and initiating containment action when quality reject found
• Supervise hourly supplier quality technicians as well as 3rd party sorting company personnel

Jan 2014 – Jul 2014 · 6 mos

• Headed new model launch for fuel efficient transmission case, capability and sampling
• Introduced and monitored test tools to help improve tool life and reduce tooling cost
• Updated and reviewed CNC programs to change/improve the aluminum machining process
• Gained experience in troubleshooting faults and machine problems on Grob’s, Excello’s, and Mag spec 500’s/600’s

Jun 2013 – Dec 2013 · 6 mos

• Supervised unionized United Auto Worked (UAW) hourly personnel and ensured that the machining line was running safely, smoothly, and producing quality parts
• Accountable for timely completion and supervision of preventative maintenance, inspections, and repairs to minimize down time
• Responsible for monitoring day-to-day production processes, tooling, and operations related to machining equipment
• Trained newly hired Process Coach’s until they were proficient in their required duties and could work independently