Lebenslauf



22467 Streamside Drive, Macomb, MI 48044

586-463-6407 (home)

email: thecoynester@

EDUCATION (combination of technical and business degrees)

Master of Business Administration (MBA): Emphases: Operations and Finance. Graduated High Distinction; top 10% of class; 72 semester hours, Brigham Young University (BYU), April 1983.

Bachelor of Science (BS): Major: Manufacturing technology processes and tools. Graduated Magna cum Laude 3.9/4.0 GPA; 142 semester hours, Brigham Young University (BYU), April 1980.

Major German Language Diploma (GDS): Documents native-like level of German language proficiency. Goethe Institute in Frankfurt and Ludwig-Maximilians-University, Munich, Germany, Nov 2000.

EXPERIENCE DETAIL (see also )

German-English Engineering Translator; KUKA Systems North America, Sterling Heights, MI. Dec 2008 – Feb 2010

Produced complete high quality illustrated translations of automotive body shop and general assembly technical specifications and drawings for new vehicle programs (more than 335,000 words in total).

Project Manager, Manufacturing Engineering (ME) Manager and Business Strategy Consultant; General Motors Corp. (GM), Warren, MI. 2001 - Nov 2008)

– Led global development of next generation general assembly plant layout, including selling executives on the project, creation of the vehicle assembly technical concept and complete redesign of the plant. Led a GM Research, MIT and multi-discipline engineering team to develop a complex technical cost model to evaluate plant design alternatives. The new layout incorporates building design features, major manufacturing equipment, conveyors, assembly process and advanced lean process supporting materials layout and lean production principles from Toyota. The new layout is the basis for all new GM assembly plants worldwide.

– Analyzed the major competitors and recommended to senior executive leadership the basis for the GM strategic globalization effort as implemented since 2003, and an expansion of the scope of production in Russia. Conducted analysis to support the selection of target production locations in Eastern Europe.

– Created strategic policy analyses used in the formulation of the US Dept of Commerce Manufacturing Policy

– Developed and applied global assembly and business process standards and facilitated the globalization of the general assembly ME and the strategic manufacturing competitive analysis organizations.

– Analyzed technical and financial impact to multiple general assembly plants of new vehicle programs and planned the production of the new vehicles.

Foreign Assignment – Project Manager, Mfg. Engr. Manager, Product Engr. (PE) Manager and Test Engineer, GM Europe (OPEL) in Germany, 1996-2001.

– Developed and administered the new product production acceptance process between GM Europe PE and GMNA ME in order to influence vehicle system designs to accommodate assembly plant requirements

– Managed prototype builds for GMNA to meet build content, schedule requirements and buildability evaluations.

– Identified and communicated to GMNA significant vehicle test events affecting the new vehicle development program in order to assure proper engineering response.

– Negotiated agreements and resolved disputes between GMNA and GM Europe executive leadership about experimental vehicles and parts acquisition requirements, vehicle test requirements, build schedule and issues.

– Negotiated and developed and managed part and vehicle procurement, shipping and financing processes

– Assisted visiting US based engineers in dealing with cultural and language differences and developed the solution for their legal concerns with German Immigrations authorities.

– Translated technical and legal documents and served as language interpreter for technical events.

Assembly Plant Mfg. Engr. and Industrial Engineering Supervisor, GM-SATURN Corp., Spring Hill, TN, 1992-1996.

– Developed the assembly process, manpower requirements, tooling and equipment for new model launches in high volume production, supervised a plant engineering team.

– Worked with UAW union representatives for improved labor efficiencies with new product introduction.

– Modified the assembly process and implemented tooling to improve efficiency, and to resolve assembly problems and ergonomic problems.

Mfg. Engr. Manager, Product Engineer, Supplier Quality Engineer (SQE), GM-SATURN Corp., Troy, MI. 1985-1992.

– Developed chassis department business processes for a new company (SATURN)

– Created product planning structure (critical path planning) and executed it from concept to high volume production with both internal and chassis supplier organizations.

– Developed and modified system designs and technical specifications, created the assembly plant process for the new parts, evaluated internal test results, coordinated product changes with other vehicle systems and with the assembly plant, released parts and systems to production.

– Supervised reporting engineers as they executed their plans with suppliers, internal engineering, purchasing and assembly process engineering.

– Selected suppliers, communicated production requirements to suppliers and assured adherence, managed supplier part development process, evaluated suppliers’ part designs, tooling and fixtures, statistically analyzed production and test data, granted design deviations and production acceptance to suppliers, worked with suppliers to solve part production problems and determined how deviating parts should be dispensed.

– Administered annual prototype parts and tools budgets ($ millions).

Research Consultant, McKinsey & Co., Inc., Cleveland, OH office 1983-1985.

– Created a discounted cash flow model based upon financial data to determine an acceptable offering price range for a major corporate acquisition by a consumer goods client.

– Built technical cost model and wrote computer program to analyze competitive cost position for major steel producers using manufacturing process formulae.

– Identified cost reduction opportunities in the transition from product development to manufacturing process for a medical products client.

Manufacturing Technology Engineer, Northrop Corp., Aircraft Division, Hawthorne, CA, 1980-1982.

– Led proposal writing team and wrote major part of winning contract proposal to USAF for Flexible Manufacturing System (FMS) study.

– Led Northrop and diverse subcontractor team in developing risk analysis methodology for FMS.

– Developed robotic fixtures and air-logic controlled smart end-effector for aluminum aircraft panel milling and drilling operations.

– Conducted original drilling research on aircraft grade titanium sheet metal for aircraft production process development.

EDUCATIONAL AWARDS

Beta Gamma Sigma Honor Society - elected 1983;

Phi Kappa Phi Honor Society - elected 1980;

MBA Dean’s List 1981-1983;

National Dean’s List 1982-1983;

College of Engineering & Technology Dean’s List 7 of 8 semesters;

Undergraduate & graduate school academic scholarships

REFERENCES (see also )

Available upon request

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