JAMES A. FINDLAY
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SR. MANAGEMENT / DIRECTOR LEVEL • ENGINEERING • OPERATIONS
Problem Resolution • Process Development & Reengineering • Capital Programs
• Team Leadership
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Results-driven and multi-task minded with a wide range of experience planning
and executing strategic initiatives that net significant financial gains. Track
record devising, evaluating and implementing positive change to manufacturing
operations, resulting in minimizing waste and reduced costs while maximizing
quality and yield. Manage multiple capital programs from cradle to grave. Lead
process planning & development of “Best in Class” manufacturing solutions.
Cost estimating. Sr. level capital justification, budget planning, risk
management. Proven record building relationships with vendors, equipment builders
and contract agencies. Self directed, “Can Do” team leader who thinks outside
the box.
Areas of expertise include…
• Capital Programs • Process Planning & Development • Design for
Manufacture • Make vs. Buy Strategies
• High Level Customer Liaison • Problem Resolution • Continuous
Improvement, Six Sigma and D.O.E.
• Capital & Department Budgets / Justification • P&L Accountability •
Component Manufacture, Assembly & Test
• Specialized Coating • Precision CNC Machining, Metal Forming & Stamping
• Aluminum & Cast Iron Molding
• Steel forging • Tool, Fixture, Gauge & Machine Design • GD&T • Team
Building • Multiple site Responsibility • Domestic & International Experience
• Strategic Thinker • Sound Decision Maker • Proven Manager
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PROFESSIONAL EXPERIENCE
Metaldyne an Asahi Tec Company, Plymouth, MI – August 2007 to Present
Automotive Parts Supplier – Estimated Annual Revenues $1.8 Billion
Corporate - Sr. Advanced Manufacturing Engineer
Report to the Director of Advanced Manufacturing Engineering – Chassis Group.
Lead Process plan and development of “Best in Class” manufacturing
solutions. Cost estimate new and replacement business. Manage multiple large
dollar capital projects. Strategic planning and cost improvement initiatives for
multi manufacturing plants (Domestic & International sites). Implement positive
change to plant operations, showing significant losses to fiscal plan. Give
direction to Engineering, Manufacturing and Quality teams in problem resolution
on major issues affecting plant P&L, customer quality and delivery. Chassis Group
technical expert in problem resolution.
Achievements:
• Reduced direct manning levels for hub production from 13 per shift to 8 per
shift while maintaining operational and quality efficiency - $750K annualized
cost improvement.
• Improved operational efficiencies and reduced scrape rates over numerous
production lines, resulting in significant reduction of expedited freight and
improved quality - $1.8M annualized cost avoidance.
• Increased the Farmington Hill, MI facilities operational efficiency average
by 21% - $106K monthly gain.
• Successfully closed the Farmington Hills facility to budget, (2) month ahead
of plan -$620K operational savings.
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TRW Automotive, Inc., Livonia, MI – September 2005 to August 2007
Automotive Parts Supplier – Estimated Annual Revenues $11.2 Billion
Principle Engineer – Corporate Advanced Manufacturing Engineering
Report to the Director of North American Operations - Cast Products Group.
Coordinate and plan multiple capital budget justifications from $1M to $18M per
program and up to $56M budget plan for multiple plant locations. Cost estimate
new programs. Manage multiple large dollar capital projects. Device, evaluate and
implement positive change to plant operations, showing significant losses to the
fiscal plan. Cast products Group technical expert in problem resolution.
Achievements:
• Launch two (2) machining cells to process past and current models service
parts - $560K annualized cost savings.
• Improved operational efficiency of two (2) coating lines - $690K annualized
cost avoidance.
• Successfully eliminated a 46% scrape issue for RT disc brake - $4.4M annual
cost avoidance.
JAMES A. FINDLAY - Professional Resume
TRW Automotive, Inc –September 2005 to August 2007 (cont’d)
Project Manager (rotor specialist) assigned to the “Delphi Contingency”
team. Establish the plan and perform the due diligence work necessary to purchase
the disc brake, knuckle and modular business from the Delphi Corporation
including all of it’s manufacturing and site assets -$500M annual sales in new
business to TRW.
Responsible engineer assigned to establish the mfg solutions and capital
strategy necessary to secure $331M annual sales in new business for 2010 MY.
Achievements:
• Business acquisition secured for TRW in the purchase of the Delphi Saginaw
Plant – January 2008 business transition.
• Secured $331M in new business for TRW for the 2010 MY.
Project Manager assigned to establish then execute the strategic plan to close
the Kingsway manufacturing facility - $4.5M Capital budget, (33) phase plan to
move (26) production lines to (4) different manufacturing locations within the
USA and Canada. Coordinate and direct project teams, plant management, move teams
and contractors. Prepare and present presentations to executive management and
high level customers.
Achievements:
• $6.0M annual benefits savings + $8.5M annual operational cost savings to
TRW.
• Achieved closure plan to budget, four (4) months ahead of schedule – $2.2M
operational savings.
Project Manager assigned to quote, process develop and launch the 2500/3500
Dodge truck disc brake & 4500/5500 Dodge truck disc brake programs - $6.2M
capital budget plan, (6) component manufacturing lines, (2) assembly cells - $70M
total annual sales.
Achievements:
• Program award to TRW – January 2006 ($70M total annual sales)
• Successful run off of the 4500/5500 Dodge truck disc brake program –
December 2006 ($11M annual sales).
• On schedule to run off the 2500/3500 Dodge truck disc brake program –
January 2008 ($59M annual sales).
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TRW Automotive, Inc., Kingsway, OH Plant – June 2001 to September 2005
379K sq.ft Machining and Assembly facility- Disc brake Rotors, Brake Drums and
Wheel Hubs
Engineering Systems Manager
Report to the Plant Manager.
Strategic Plan: Turn the plant around from showing monthly losses to become a
robust and profitable facility.
Mentor and lead a total of nine professionals (direct reports).
Manager responsible for all engineering functions of the Kingsway manufacturing
facility.
Directed all engineering activities necessary to meet or exceed the operational
plan expectations for profit, capital spending and cost reduction goals. Further
develop and improve the engineering infrastructure and systems. Empower the
engineering team to support operations and quality in order to meet the
customer’s expectations for quality, delivery and cost. Direct and facilitate
all activities related to new capital programs being implemented into the
Kingsway Division. Proponent of Continuous Improvement, Lean Manufacturing, Total
Quality and Six Sigma.
TRW Cast Products – Advanced Manufacturing Engineering Group Lead Manager
responsible for the creation and development of “Best in Class” manufacturing
strategies. Cost estimate for new programs. Coordinate, plan and justify capital
spending budgets for multiple manufacturing locations. Sr. Management, customer
and supplier plant liaison. Cast products Group technical expert in problem
resolution.
Achievements:
• Successfully improved the Kingsway plants overall product quality and
product line efficiency bringing the operational performance from a seven day
work week to a 5 day work week by end of Q4 2001 – $1.4M annual savings.
• Improved the Kingsway plants P&L from monthly losses to an average of 14%
profit (17% eva as the high to 6% eva as the low) - $28M average annual profit.
• Successfully quote and secured $103M in annual sales (6.9M units) in new &
replacement business.
• Plan and justify capital budgets of $1M to 10M per program and up to $38M
budget plan for multiple plant locations.
• Successfully launched 4 new production lines into the Kingsway plant ($12.5M
in annual sales).
• Implemented cost reduction initiatives totaling in excess of $1.2M annual
savings through lean manufacturing, six sigma and VAVE initiatives.
JAMES A. FINDLAY - Professional Resume
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TRW Automotive, Inc. - Livonia, Michigan – August 1997 to June 2001
(January 2001 to June 2001) -Interdepartmental transfer
TRW Automotive, Inc. – Woodstock Division
360K sq.ft Machining and Assembly facility- Disc brake Rotors, Brake Drums and
Wheel Hubs
Corporate Staff Manufacturing Engineer
Report to the Director of Advanced Manufacturing Engineering – Cast Products
Group.
Lead engineer responsible for managing all new capital programs implemented into
the Woodstock Division. Manage process planning, timing and cost. Oversee the
purchase, installation and runoff of production equipment. Coordinate and direct
project teams, vendors, equipment builders and contractors. Corporate
engineering, quality and customer plant liaison. Lead team initiatives for
process development and quality improvements.
Lead Engineer responsible for quoting new and replacement business for the Cast
Products Group. Develop “Best in Class” manufacturing solution, process
planning, overhead allocation, capital and tooling budgeting.
Participate in Lean Manufacturing and Total Quality Initiatives. Cast products
Group technical expert in problem resolution.
Achievements:
• Manage TRW Cast Products Groups cost down initia |
