Lead Process /  Manufacturing Engineer, New Programs
            Multimatic Inc. (Inmet)     www.multimatic.com

A Canada-based privately-held global enterprise supplying engineered components, systems and services to the automotive industry (Tier 1 &2). Multimatic’s core competencies include the engineering and manufacturing of complex mechanisms, body hardware, suspension systems and body structures, as well as the design and development of lightweight composite automotive systems. In addition, Multimatic delivers niche vehicle design, development and production for road and race car applications. Approximately 2000 employees, multiple facilities globally,  518M annual revenue.

 Responsible for; quoting of manufacturing processes, manufacturing engineering of product design on FSS (Full Service Supplier) products, process design, plant layout, process equipment procurement installation and Buy off.  The process engineering department consisted of between 8-12 process engineers and Co-op engineering students, Responsible for leading and mentoring the department in day to day operations and for the development of the departments’ standards of engineering change and operational processes.  Created approximately 14.7M in cost avoidances based on contract length and another 2.3M annually.

Projects:
  Plant Logistics, consolidation.

  General Motors GMT900 Cross Car Beam
  Mazda J56 Cross Car Beam
  General Motors GMT355/345 Cross Car Beam
  Chrysler WK/XK Cross Car Beam
  Chrysler Seat Riser assemblies
  Ford V229 Cross Car Beam, Air Bag chute and Door, Storage Bin steels
  Ford PHN131 Cross Car Beam, Mod Plate, Hush Bracket, Second L Bracket
  Created Equipment & RFQ, Standards
  Engineering change system development
  MRP system Bill of material accuracy

Cost Avoidance Examples:

Material Handling Innovation - Cost Avoidance $4.7M
Designed and implemented a new type of material handling system eliminating the need for 50% of the material handling equipment and maintenance budgeted.                             

Design for Manufacturer - Cost Avoidance $3.8M      
Drove the redesign of a product (Tube) to allow for the use of a different simpler type of processing resolving processing capability and robustness issues and eliminating large expendable tooling costs.

Staff Requirement Reduction - Cost Avoidance $2.8M$ - $3.3M
Designed a returnable magazine for one of the purchase components (tubes), eliminating several material handling safety concerns, removing a material handler on each of 3 shifts, eliminating 10 truckloads of refuse dunnage and the associated costs per year, saving the Vendor enough in labour and dunnage to provide the containers and a product give back.  

Plant Logistics Project - Annual Cost Avoidance $2.3M
Analyzed inventory and logistics practices, determined proper stocking levels and planning parameters to suit the business needs, put the parameters in place and laid out the facility to accommodate the new plan.  Consolidated 4 separate off-site warehouses into one within the main production facility.                    

Staff Requirement Reduction Through Automation - Cost Avoidance $2.0M                        
Designed a loader to automatically load the above-mentioned tube into the material handling system eliminating the need for 2 material handling staff on each of 3 shifts.     

Staff Requirement Reduction Through Automation - Cost Avoidance $0.9M

Designed and implemented a material handling device for manipulating final product containers, reducing the work required by over 50% and eliminating the need for one material handling staff on each of 3 shifts

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