Description
Accomplishments Manufacturing Engineering: Drove the design and implementation of new lean automated manufacturing facilities, including fabrication, powder coating, and assembly operations in support of new product releases. Grew & developed a mature engineering organization to support operational requirements internally including automation, tool design, packaging design, and Tool & Die functions. Defined capacity planning models to identify manufacturing constraints based on production forecast, and implemented multimillion dollar CapX programs to eliminate them. * Increased production rates for Genesis and Summit lines by 100% through implementation of automation, improved ergonomics, and improvements in line flow. * In support of above operations, increased Fab capacity through the facilitation and implementation of 1 800T press, 2 600T presses, and 2 300T presses. In addition we increased Tool & Die capacity to support maintenance of increased volume and size of dies. * In order to support the growing internal demand for new T & D builders, we implemented an internal apprentice program in association with TMA. David Lohbauer Page 2 * Increased production rate for Q products by 40% through implementation of internally designed & built assembly automation. In order to support increased volumes we proportionately increased tooling efficiency and line speed for powder coat operations. * Increased Charcoal capacity by 30% through the addition of a 3rd draw line, increasing furnace capacity, and improvements in powder coat efficiencies including robotic reinforcement developed in house. * Integrated the change control process from a manual to an automated work flow within SAP to reduce cycle time and improve accuracy. * Improved packaging concealed damage through design of products to exceed ISTA design standards. Quality Management: Implemented a global quality system supporting all manufacturing operations and global customer service organizations with KPI's to drive performance. Enhanced internal global lab capabilities in US and China to support the new product development process, ISO compliance, PPAP, and ALT testing. Led global customer service organizations to identify and address critical product field metrics. * Corporate COQ reduced by 50% through reductions in global field claims, improvements in internal quality and appraisal costs. * Genesis, Spirit, Q, and Charcoal product line field failure rates below 0.5% through the analysis of field returns and implementation of internal quality systems. Measureable improvements seen in damage, missing parts, corrosion claims, and thermal events. * Manufacturing FPY for most operations exceeded 98% as a result of monthly QSR meetings. ICAR process implemented to address nonconforming internal processes. * Supplier quality for all incoming materials improved over 80% to 1000 PPM. This was a result of the implementation of SCAR process & QIP meetings with suppliers that did not meet quality targets. * Dock to Stock initiative improved 95% for purchased components that meet requirements. * PPAP on new products increase from less than 10% to 100%, and internal lab facilities capacity increased to support the workload. Developed ISO compliance between lab facilities in the US and China * Managed the Document control function for internal and external specifications. Daily internal audits performed to ensure controlled specifications are followed, and systems are operating within defined SPC control limits. As a result there have been no findings from external supplier and regulatory audits. Development Engineering: Managed multidiscipline design teams for new product development from concept to production release of mobile phones and linear power amplifier base station equipment. * Led the Mechanical Engineering development for the first Linear Power Amplifier program * Led cross functional Mechanical and Electrical development of the next generation Expandable Linear Power Amplifier program that reduced footprint by 30% * Led the Mechanical design effort for the first mobile handset to use a blue LED display and joystick control function * Led a cross functional Mechanical and Electrical team in conjunction with a 3rd party government contractor to provide secure communication of the base mobile platform. Project Management: * Recipient of the 1998 CEO Quality Award for Project Management for consistently meeting project goals on schedule and on budget.
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