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Resume of GES
Consultant

EXPERTISE AND SERVICES

Mechanical Engineer, Design Engineer, Engineering Consultant, Engineering Failure Analysis, Accident Investigation, Accident Reconstruction, Specialist, Forensic Analysis Investigation Expert, Patent Infringement, Expert Witness Testimony, Engineering Consulting Services
Expertise in developing profitable automotive manufacturing operations, six sigma methods and quality improvement, Kaizen, TPM and Taguchi, lean manufacturing, QS-9000, new product model design, customer coordination, supplier selection, process design, prototype build, and launch.

Specialization includes green field automotive plant, customer contact and gray box design, site selection, manufacturing layout, build supervision, robotic process cell creation and assembly pallet line installation, staff selection and training, and production launch, and automotive part design

PRINCIPAL INDUSTRIES SERVED
Assembly, Automotive, Machine Tools, Metal Processing, Machining

EDUCATION
B.S., Mechanical Engineering, University of Cincinnati, Cincinnati, Ohio

PROFESSIONAL EXPERIENCE
Consultant, Kevin Kennedy & Associates, Inc.

Providing mechanical engineering consulting, project management, design engineering, engineering consulting, failure analysis, forensic engineering, and related expertise to a wide variety of clients.

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Case Studies

Project Manager, Designer and Supplier of Transportation-Related Metal Formed Components

Supervised team of 6 engineers and 26 toolmakers. Converted $2.4 million/yr. loss into $5.0 million profit by overcoming start-up challenges using six sigma methods and quality improvement projects. Used Kaizen, TPM and Taguchi to reorganize process for making a tier 1 transmission part which bankrupted a sister plant. Represented plant on customer cost improvement project and saved a total of $500,000 by inventing and obtaining approval for a part redesign. Overcame severe capacity problems by using lean manufacturing to improve output by 20%.

Project Manager, MAGNA (TESMA)

Supervised 4 engineers and three mechanics. Landed and implemented $45 million of new business. Turned $2 million loss into $6 million profit by obtaining QS-9000 certification, creating business plans, and quote model and launching an entirely new product mix for the plant from original customer contact through PPAP and volume launch. Received patent during oil pan launch including Unigraphics solid model design, customer coordination at Lotus in England, supplier selection, process design, prototype build, and launch.

Engineering Manager, Burlington Die Casting, Burlington Technologies

Was responsible for implementing all new work, supervising 6 team members. Spearheaded teams which designed and volume launched $30 million worth of new tier one automotive business obtaining the first Ford Q1 for our commodity.

Project Manager, Alumetco, Burlington Technologies

Was responsible for implementing a green field automotive plant including customer contact and gray box design, site selection, manufacturing layout, build supervision, robotic process cell creation and assembly pallet line installation, staff selection and training, and production launch. Turning the first monthly profit two years after ground breaking.

Tool Engineering Supervisor, Etobicoke Casting, Chrysler

Was responsible for supervising a team which implemented $30 million in new work. As plant engineering contact spent 1 day per week at customer, invented launched and PPAPed a new family of pistons to replace entire $25 M piston output.

Design Engineer, Chrysler Highland Park Headquarters, Chrysler

Was responsible for designing parts in three UPG for all Chrysler vehicles. Designed and shepherded through assembly plant launch 1/30 of all K-body and Chrysler mini-van components.

PUBLICATIONS
Patent holder for automotive oil pan.

Please note that this is an abbreviated CV. A fully detailed unabridged CV is available under special circumstances.

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Case Studies

Mechanical Engineer, Design Engineer, Engineering Consultant, Engineering Failure Analysis, Accident Investigation, Accident Reconstruction, Specialist, Forensic Analysis Investigation Expert, Patent Infringement, Expert Witness Testimony, Engineering Consulting Services
Resume of IFT mechanical and manufacturing engineer, design for manufacture and assembly consultant, mechanical systems design consultant, new product introduction, process improvement, engineering failure analysis, accident investigation, accident reconstruction, specialist, forensic analysis, investigation, product liability, expert witness testimony, patent infringement, expert witness testimony, engineering consulting services
Resume of JMG mechanical engineer, engineering manager, product design and documentation, engineering consultant, fatigue failure analysis, accident investigation, accident reconstruction, specialist, forensic analysis, investigation, product liability, expert witness testimony,
Resume of BZU mechanical engineer, metallurgical engineer, metallurgist, advanced materials processing consultant, production engineer, research and development consultant, powder metallurgy consultant, engineering failure analysis, accident investigation, accident reconstruction, specialist, forensic analysis expert, patent infringement, expert witness testimony, engineering consulting services
Resume of GEF industrial engineer, automotive product and process engineer, lead manufacturing engineer, value analysis / value engineering specialist, global product standardization engineering consultant, quality engineer, failure analysis, expert, engineering consulting services

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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax

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