Summary
Overview
Work History
Education
Skills
Timeline
Generic

Kenneth P. Kastner

Jenison

Summary

Dynamic Project Engineer with established expertise at SA Automotive, excelling in product development and process optimization.

Overview

35
35
years of professional experience

Work History

Project Engineer

SA Automotive
Webberville
04.2017 - 05.2025
  • Company Overview: Automotive Interiors, headliners, load floors, nonwovens
  • Reviewed design specifications, and part performance requirements.
  • Benchmarked comparable products on the market.
  • Using a decision matrix, evaluated and compared multiple design concepts / alternatives to narrow down options for construction.
  • Developed prototype form and bond tools to evaluate construction options meeting customer strength and thermal targets.
  • The unique product characteristics required developing a two step process. Molding then fabric bonding and edge-wrapping.
  • Provided raw material costing for substrate, face fabric and injection molded components.
  • Tooling quoted: Forming, punching, water jet fixtures, fabric bonding, injection molds, multiple assembly stations and check fixtures.
  • Created process flow steps with timing and labor requirements for product costing development.
  • Supported design verification builds for testing to customer specifications.
  • Ensured customer specifications and testing timing expectations were met by communicating clearly and regularly with the test lab.
  • Created standard work instructions for each process, to ensure work was performed correctly.
  • Worked closely with a tooling company to develop edge-folding equipment for the sunroof opening.
  • Worked with multiple suppliers, customers, production personnel and maintenance to build tooling, fixtures, and equipment.
  • Developed a unique non-woven construction to improve sound absorption for Ford, while meeting strength and weight requirements.
  • Developed a reversible load floor with carpet on one side and PUR over mold on the other side.
  • Led equipment procurement and installation of equipment for SA Puebla facility to manufacture this in Mexico.
  • New equipment procurement and processes developed for Tesla Model 3 Headliner for SA Reno NV.
  • Heating a headliner substrate locally then edge wrapping a face fabric, pressing and cooling for good bond.
  • Automation of manual face fabric cutting.
  • Robotically applying PUR adhesive to the 'B' side of a headliner, then automated placement of multiple back components.
  • Automated speaker grill tab bender for headliner.
  • Manual station to add head impact countermeasures, retaining clips, and speakers to back of a headliner.
  • Manual station to install coat hook, center check and light consoles to back of a headliner.
  • Manual station to add stuffer blocks, foam pads, glue wire harness to back of headliner.
  • End of line tester to verify function of speaker, light consoles, microphone and visor continuity.
  • Automated inspection station to verify components.
  • New processes developed for Ford CX482, CX483, U625, U611 PUR load floor.
  • Roll coating PUR adhesive on carpet for application to a load floor substrate, then edge wrapping for clean finished part.
  • Handle assembly tables with Poke Yoke features to ensure quality.
  • Check fixtures to ensure part meets print requirements.
  • New process / product developed for Jeep Cherokee molded carpeted rear quarter trim component.
  • Sound barrier laminated with PSA die-cut for application to back of molded part.
  • Stations to properly locate and apply laminate to molded parts.
  • Spearheaded product problems through a structured root cause analysis, then developed and implemented countermeasures.
  • Responsible for developing process flow diagrams, PFMEAs, control plans, DFMEA’s, work instructions.
  • Managed product performance validation tested with multiple suppliers through product development stages.
  • Automotive Interiors, headliners, load floors, nonwovens

Corporate Manufacturing Engineering Manager

Corvac Composites, LLC
Kentwood
01.2016 - 02.2017
  • Company Overview: Sheet Extrusion / Thermal Forming -Automotive
  • Extrusion Sheet scrap was reduced by $30K/month, initiated team, focused root cause analysis.
  • Replaced worn extrusion screws and repaired melt pumps resulting in 30% increased throughput.
  • Reduced Specific Energy Consumption from 2.5 to 2kWhr/kg on 2 extrusion lines $46K annual energy savings.
  • Used DOE to determine main variables effecting sheet orientation, warpage of twin sheet molded parts.
  • Initiated operator teams where they control idea implementation & process improvements.
  • Developed layout to incorporate moving all equipment from a closing Indiana plant into Michigan plant.
  • Sheet Extrusion / Thermal Forming -Automotive

Product / Process development Engineer

Concept Industries, Inc.
Grand Rapids
09.2000 - 11.2015
  • Company Overview: Nonwovens / Thermal Forming - Automotive
  • Lead a variety of advanced manufacturing, facilities, plant layout, and continuous improvement projects.
  • Analyzed manufacturing process, utilized improvement methods to impact quality, cost reduction and throughput.
  • Planned, directed and coordinated capital projects and manufacturing processes across multiple projects/programs.
  • Manufacturing principles (quick change, error proofing, visual management, kaizen, value stream mapping, 5S, problem solving, standard work, line balancing).
  • Developed natural fiber reinforced polymer composite molded parts for interior and exterior automotive trim.
  • Developed natural fiber alternative to fiberglass for office panel application.
  • Developed engineering & material specifications, and design validation test plans.
  • Managed engineering change release and notifications.
  • Responsible for IMDS, MSDS, REACH, & GADSL compliance.
  • Project management skills, engineering quote activities and prototyping.
  • Optimize product cost through material selection / utilization and rational processes.
  • Creative, inventive, open-minded approach resulted in two patent applications.
  • Nonwovens / Thermal Forming - Automotive

Plastic Honeycomb Core business unit manager

Plascore, Inc.
Zeeland
01.1996 - 09.2000
  • Company Overview: Profile Extrusion, Polycarbonate, Polypropylene - Automotive
  • Responsible for operation results of business unit.
  • Increased Sales performance from $3.5 million to $5.3 million in 4 years.
  • Piloted team based environment in which nearly every operational index was improved.
  • Developed a new division making polypropylene honeycomb cores with scrim for sandwich composite products.
  • This involved procurement of two co-extrusion lines, thermal bonding equipment, cutting and laminating equipment.
  • Profile Extrusion, Polycarbonate, Polypropylene - Automotive

Plant Engineer

Rehau Inc.
Sturgis
06.1990 - 01.1996
  • Company Overview: Profile Extrusion, PVC - Furniture
  • Managed plant / product / maintenance / tooling engineering functions– improved efficiency PM, quick die change, reduce scrap.
  • Used statistical analysis to optimize PVC formulation.
  • Managed 40,000 square foot expansion of plant, to support five new profile extrusion lines.
  • Established process monitoring systems to sharpen focus where needed.
  • Supported new product introductions, create standardized work instructions.
  • Measured process variation, performed designed experiments, reduced variation and waste.
  • Profile Extrusion, PVC - Furniture

Education

Bachelor of Science - Manufacturing engineering, Plastics Technology Option

Western Michigan University
Kalamazoo, MI
01.1990

Associate of Science - Industrial Engineering Technology, Industrial Electronics option

Lake Michigan College
Benton Harbor, MI
01.1986

Skills

  • Project management
  • Process optimization
  • Product development
  • Design verification
  • Root cause analysis
  • Material selection

Timeline

Project Engineer

SA Automotive
04.2017 - 05.2025

Corporate Manufacturing Engineering Manager

Corvac Composites, LLC
01.2016 - 02.2017

Product / Process development Engineer

Concept Industries, Inc.
09.2000 - 11.2015

Plastic Honeycomb Core business unit manager

Plascore, Inc.
01.1996 - 09.2000

Plant Engineer

Rehau Inc.
06.1990 - 01.1996

Bachelor of Science - Manufacturing engineering, Plastics Technology Option

Western Michigan University

Associate of Science - Industrial Engineering Technology, Industrial Electronics option

Lake Michigan College

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