Matt Wiljanen
Manufacturing / Industrial Engineer
Brighton,MI
Summary
Diversified Manufacturing / Industrial / Process Engineer offering 30 years of experience with expertise and knowledge in the areas of Production Operations, Quality Management, Manufacturing Systems, Launch Coordination. Highly successful in Lean systems recognized by Harbour and Associates as “Best in Class” for vehicle manufacturing on two occasions at Jefferson North Assembly Plant, 2006 and 2007. Experience in Manufacturing Cost Estimating and Program Finance.
Manufacturing professional with strong background in optimizing production processes and implementing cost-effective solutions. Highly focused on team collaboration and achieving measurable results. Recognized for adaptability and reliability in dynamic environments, with expertise in lean manufacturing and process improvement.
Overview
34
34
years of professional experience
Work History
Industrial / Manufacturing Engineer
Tribar Manufacturing
07.2023 - Current
- Plants include Mold / Paint / Plate and Assembly Centers.
- Responsible for line layout, set up, process flow and manpower.
- Create Standard Work Instructions, Quality Diagrams.
- Responsible for team budgets, equipment requirements and job training.
- Plan and implement quality improvement initiatives.
- Responsible for ergo mapping jobs and safety initiatives.
- Responsible for all manpower and efficiency improvements.
- Involved in all aspects of SQDCM (Safety, Quality, Delivery, Cost and Moral).
MCF Interior Program Consolidator - 25MY Expedition / Navigator
Ford Motor Company
05.2021 - 09.2022
- Provide Financial support for the Interior Systems VHM by collaborating closely with PD Programs, Purchasing and Engineering.
- Handle and provide analytical support for assigned commodities across multiple vehicle programs.
- Support for Team of 4 for material cost and vendor tooling targets/status throughout the sourcing process.
- Maintain and update accurate part-level reporting, identify risks & opportunities.
- Analyze large data and provide ad-hoc support for business cases and special projects.
- Identify and explore cost reduction opportunities (piece price, tooling, ED&T).
- Interior Systems Finance Liaison for a 25MY Expedition / Navigator.
- Work with PD Finance to provide support for vehicle landmark reporting.
- Provide program financial status and variances.
- MCF Finance lead for Seat Structures.
PDC Engineering Programs Finance Analyst
Ford Motor Company
07.2019 - 05.2021
- Responsible for vehicle program PRM Agreements for finance reporting milestones (PS, PSC, PA).
- Develop yearly Program SoMP reports.
- Complete monthly program financial report cards.
- Coordinate and maintain any program-to-program financial target transfers.
- Work with Program Finance, Engineering and Program Management to resolve finance target and status issues.
Manufacturing Cost Optimization Engineer
Ford Motor Company
05.2013 - 07.2019
- Develop piece cost and tooling estimates for assigned commodities which requires an extensive understanding of manufacturing cost structure and supply base capability.
- Support forward and current model programs.
- Support teardowns, benchmark best practices, and identify material cost reduction opportunities.
- Ability to construct and analyze manufacturing costs by reviewing sketches, engineering data, and functional information.
Manufacturing Engineer - K2XX Program (CKGP – Contract)
General Motors
09.2011 - 05.2013
- Integrate Lean Manufacturing and GM-Global Manufacturing System (GMS) principles into Future Product Programs.
- Utilize Industrial Engineering tools for operation and layout analysis; including predetermined time systems, ergonomic assessment, scrolling, throughput improvement, etc. - identify and support resolution of issues.
- Develop and drive the Continuous Improvement and PRTS Processes, function as co-lead of IRT.
- Develop vehicle build sequence and manpower impact from rough to fine line balance, as defined by program timing.
- Develop and apply Lean Material Strategies (LMS).
- Work with Process Development Teams to drive common processes and lean buildable designs.
- Drive development of system and workstation layouts.
- Complete the technical portion of the MAAC Statement of Requirements (SOR) for all tools.
- Work with ME Virtual Simulation Team to apply math tools and develop a functional workstation.
- Lead tool development (both fixture and handheld), facilitate equipment and conveyors to ensure proper operator interface and location for plant installation.
- Provide direction for the design, build, installation, debugging and tryout of all workstations to ensure a successful launch.
- Develop Manufacturing Planning Study (MPS) inputs for assigned areas. Manage the tooling budget to the appropriated dollars.
- Support PFMEA processes - analyze quality risk factors and develop appropriate product, process and tooling countermeasures.
Assistant Production Manager
Koppert Biological Systems
01.2010 - 08.2011
- Responsible for all aspects of production including Mating, Hibernation, Installation, Selection and Expedition of live bumble bees.
- Installed SQDCM processes and introduced lean concept to the shop floor.
- Streamlined expedition process, resulting in a (6) head manpower reduction while raising thru put 60%.
- Implemented numerous efficiency improvements.
- Cut pollen consumption by 40% by introducing a pre- cut piece size pollen concept.
Industrial Engineer
PILOTS LLC, New Venture Gear
03.2009 - 12.2009
- Contract assignment for Magna
- Responsible for reviewing Job Setter CNC / Tooling changeover practices, documenting actual processes required, and streamlining procedures to eliminate waste.
- Developed specific process sheets for each component and Standard Work Instructions (SWI's) for each operation.
- Responsible for ergo mapping jobs and safety initiatives for all documented processes.
Industrial and Operations Engineering Supervisor
Chrysler LLC, Jefferson North Assembly Plant
11.2005 - 11.2008
- Lead IE responsible for a team of six direct report Industrial and Operations Engineers.
- Responsible for manpower forecasting and budgets; current and future for JNAP.
- Lean Manufacturing Champion responsible to represent JNAP at all cross functional platform launch meetings.
- Principle plant Interface for all future vehicle programs and launch activities.
- 2011 WK / WD Program IE Launch Lead responsible for (TCF) assembly center station changes.
- Developed, implemented and maintained plant assembly center scroll for 2011 Pilot Program and Digital Build Process.
- Work hand in hand with AAME / AME / Product Engineering / Production Control on all JNAP future launch issues.
- JNAP launch representative for 2011 WK / WD PPIW and PFMEA processes.
Industrial and Operations Engineer
DaimlerChrysler NA, Jefferson North Assembly Plant
10.2002 - 11.2005
- Plant includes BIW, Paint Shop and Assembly Center.
- Responsible for line layout, set up, process flow and manpower.
- Create Standard Work Instructions, Quality Diagrams.
- Responsible for team budgets, equipment requirements and job training.
- Plan and implement quality improvement initiatives.
- Responsible for ergo mapping jobs and safety initiatives.
- Responsible for all manpower and efficiency improvements.
- Involved in all aspects of SQDCM (Safety, Quality, Delivery, Cost and Moral).
Zone Coordinator (Production Supervisor)
Chrysler Corporation, Jefferson North Assembly Plant
03.1998 - 10.2002
- Responsible for the day-to-day operations of four zones in Final Assembly.
- Manage up to 85 union employees with regard to manpower adjustments, training, attendance, safety, quality, delivery, cost and morale. Responsible for issuing discipline as required.
- Responsible for all electrical testing operations of vehicle.
- Assembly Quality Champion - responsible for initiating all assembly QTS response plans and initiate corrective actions leading to continuous improvement.
- Acting Area Manager when required.
Local Content Manager - S.E. Asia Operations
Chrysler Corporation, Jeep Special Programs Engineering
12.1995 - 03.1998
- Principle interface with all S.E. Asia affiliates for all Jeep Issues.
- Chair cross functional S.E. Asia weekly team meeting.
- Travel internationally to interface with affiliates, ex-patriots with regard to ongoing operations to support launches, to gain clarification on field issues and establish closure on engineering issues.
- Planned, developed and implemented all local content components for CKD builds in Thailand, Malaysia and Indonesia.
- Principle interface with Chrysler International Operations, International Manufacturing, International Supply and International Purchasing for all local content related issues.
Program Specialist - S.E. Asia Programs
Chrysler Corporation, Jeep Special Programs Engineering
03.1995 - 12.1995
- Issue EPDB bulletins and updates for X1 CKD programs.
- Support all aspects of S.E. Asia CKD program and CKD Product Strategy Team.
- Monitor engineering changes and notify affiliates of possible part to part compatibility issues.
- Responsible for the establishment, publication and maintenance of the X1 Engineering Program Description Book.
- Support International Operations planning activities.
Sales / Program Coordinator
Lear Corporation
03.1994 - 03.1995
- Responsible for tracking all engineering changes from initial to final phase.
- Responsible for recovering tooling dollars, negotiating cost discrepancies, issuing sales authorizations, BOM Coordination, piece price cost adjustments and providing program cost analysis.
Account Representative
Detroit Air & Electric Tool Service
07.1992 - 03.1994
- Establish and manage an outside sales territory in the power tool industry.
- Service accounts with pneumatic, electric and hydraulic tooling dealing with OEM, Tier 1 and after-market suppliers.
Account Representative
Premier Industrial Corporation
11.1991 - 07.1992
- Responsible for managing an outside sales territory servicing fasteners and cutting products to automotive industry accounts.
- Executed product demonstrations in a plant environment.
Education
Bachelor of Science - Political Science, Secondary Education
Kent State University
Kent, Ohio05.1991
Skills
- Proficient in using Microsoft applications
- Proficient in MQAS / QS9000 / ISO9000 / many quality systems
- Workplace Violence Prevention
- Problem Solving Root Cause Analysis Workshop
- Lean Knowledge & Assessments Training
- Manpower Optimization
- Applied Ergonomics
- Proficient in leadership of small and large groups
- Individual Leadership Training
- Vehicle Duty Cycle Training
- Workstation design
- Assembly line optimization
- Manufacturability improvements
- Value stream mapping
- Industrial engineering
- Cost reduction programs
- Root-cause analysis
- Lean manufacturing
- Continuous improvement
- Decision-making
- Manufacturing processes
- Process improvement
- 5S methodology
- Process development
- Waste reduction
- Procedure documentation
- Failure modes and effects analysis
Motion study
Facility layout
Staff supervision
Harbour Award 2006, 2007
Best in Class for Hours Per Vehicle - Jefferson North Assembly Plant (JNAP) - Detroit MI.
Timeline
Industrial / Manufacturing Engineer
Tribar Manufacturing
07.2023 - Current
MCF Interior Program Consolidator - 25MY Expedition / Navigator
Ford Motor Company
05.2021 - 09.2022
PDC Engineering Programs Finance Analyst
Ford Motor Company
07.2019 - 05.2021
Manufacturing Cost Optimization Engineer
Ford Motor Company
05.2013 - 07.2019
Manufacturing Engineer - K2XX Program (CKGP – Contract)
General Motors
09.2011 - 05.2013
Assistant Production Manager
Koppert Biological Systems
01.2010 - 08.2011
Industrial Engineer
PILOTS LLC, New Venture Gear
03.2009 - 12.2009
Industrial and Operations Engineering Supervisor
Chrysler LLC, Jefferson North Assembly Plant
11.2005 - 11.2008
Industrial and Operations Engineer
DaimlerChrysler NA, Jefferson North Assembly Plant
10.2002 - 11.2005
Zone Coordinator (Production Supervisor)
Chrysler Corporation, Jefferson North Assembly Plant
03.1998 - 10.2002
Local Content Manager - S.E. Asia Operations
Chrysler Corporation, Jeep Special Programs Engineering
12.1995 - 03.1998
Program Specialist - S.E. Asia Programs
Chrysler Corporation, Jeep Special Programs Engineering
03.1995 - 12.1995
Sales / Program Coordinator
Lear Corporation
03.1994 - 03.1995
Account Representative
Detroit Air & Electric Tool Service
07.1992 - 03.1994
Account Representative
Premier Industrial Corporation
11.1991 - 07.1992
Bachelor of Science - Political Science, Secondary Education
Kent State University
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