Open To Work
Richard Morabito
Grosse Ile,MI
Summary
Dynamic design engineering leader specializing in cost-effective EV strategies, driving $152 million in savings and overseeing a $900 million tooling budget. Led transformative projects that achieved up to 35% cost reductions in battery design, fostering cross-disciplinary collaboration and operational excellence.
Overview
45
45
years of professional experience
3
3
Certifications
Work History
Head of Cost Engineering and Tooling Expert
Slate Motors
Troy, US
07.2023 - Current
- Managed $400M tooling budget for full vehicle, ensuring optimal allocation of resources.
- Collaborated with sourcing on tooling, gages, fixtures, testing, and engineering design, contributing to $80M in cost savings.
- Lead Battery Design Battery Module Structures to lower cost by 35%.
- Lead BIW and Chassis Engineering cost reductions by 18%.
- Lead Interior and Seat Engineering cost reductions by 22%.
- Identified and partnered with new low-cost suppliers across all commodities, enhancing procurement efficiency.
- Report results to CEO and leadership teams monthly.
- Working with the Engineering and Purchasing groups, and the Studio to supply engineering BOM models to build the $25K EV Pick -up by 2026.
Senior Cost Engineering Manager
Nikola Motor
11.2022 - 10.2024
- Led cost engineering group with aPriori software to target full vehicle cost reduction of 30% - 35% in collaboration with engineering, purchasing teams, suppliers, and design studios.
- Managed a team of engineers to develop and deliver complex engineering projects on time and within budget.
- Developed processes for monitoring and evaluating engineering project performance metrics, enhancing project delivery effectiveness.
- Analyzed data from engineering projects to identify areas for improvement in product design, development process, and cost efficiency.
- Utilized Apriori software to analyze CAPEX data, uncovering cost-saving opportunities that informed strategic decisions.
- Applied Apriori software to assess piece costs, resulting in a savings of $822.
- Lead battery design to reduce costs by 25%.
- Assisted in designing high-voltage cables that reduced costs by 10% through innovative materials.
- Recruited two advanced cost engineers to provide mentorship and training for improved team performance.
Lead Cost Engineer and Tooling Expert
Rivian Automotive
06.2020 - 12.2022
- Led investments in tooling capital expenditures to align with Apriori cost models.
- Reviewed project plans, specifications, and change orders to assess and communicate cost impacts effectively.
- Interpreted and analyzed cost data to develop cost estimates for projects.
- Reduced engineering bill of materials costs by $4,000 through strategic sourcing.
- Performed financial analyses, including cash flow projections and break-even analysis, to support informed decision-making.
- Prepared detailed project progress reports, highlighting discrepancies between estimated and actual costs to inform stakeholders.
- Researched new technologies or products that could reduce costs for future projects.
General Manager R & D
Gecom Corporation
US
01.2020 - 06.2020
- Lead product development group of 35 engineers.
- Led product development group in Novi Michigan, focusing on innovation and project execution.
- Managed a team of 50 direct reports in design engineering and testing to ensure project completion.
- Design new low-cost latches for Toyota and Honda.
- Support new cost targets for all new commodities with Toyota, Honda and Nissan.
- Lead design reviews and DV test results in production.
- Managed lab operations in Novi Michigan for design validation and product verification testing.
- Oversaw budget management to drive bottom line growth and identify new sales opportunities.
- Respond quickly to meet customer needs and resolve problems while building up new business.
- Quote new business with all OEMs and review with President of Gecom.
Lead Engineer Interiors & Exteriors
Waymo LLC (Google Self Driving Project)
03.2016 - 02.2020
- Leading interior design and engineering group on multiple projects with the following tasks, DFM, CAD, and CAE, DVP and support building vehicles for early rider feedback programs.
- Project leader within group interfacing with product teams and ID groups to finalize designs for production.
- Designed interior packaging for OEM on two platforms (FCA, JLR), ensuring alignment with production requirements.
- Lead with sourcing of interior parts with Global Supply Teams.
- Identified new supplier technology for tooling plastic part assemblies to enhance self-driving sensor team capabilities.
- Led design engineer CAD reviews and set up product reviews with the CEO and leadership teams.
- Catia V6 Design CAD skills and advanced prototype simulations for testing and validation.
- Working with new OEM on upfront opportunity in packaging SDS into upcoming new platforms.
- Six patents on new interior components for self-driving systems teams.
Lead Principal Engineer
GM Interiors
Warren, US
01.2015 - 01.2016
- Collaborated with interior team to resolve launch issues alongside engineering team and external suppliers.
- Coordinated with GM studios on feasibility studies for new interior programs across Cadillac platforms.
- Assisted Engineering Group Manager in managing new supplier projects and identifying cost reduction opportunities.
- Mentor within engineering groups to solve design issues on new programs, or current programs.
Project Chief Engineer Interior
Chrysler Fiat Automobiles
Auburn Hills, US
01.2013 - 01.2015
- Manage engineering team and supplier base, lead tooling and manufacturing costing and timing activities.
- Managed tooling budgets, sourced and negotiated prototypes and production, and resolved tooling feasibility issues.
- Reviewed program timing and deliverables, achieving cost, time, and weight reductions at component level for engineering MGR.
- Eliminated inner cover snaps, reducing piece price by $22.
- Reduced production tooling $7.2mm by leading common mechanisms and structures on all three rows for base programs.
- Reduced weight on quad seat structures 1.0lb reduction.
- Achieved OKTT base approval for QAF base and PHEV projects.
- Prototyped all parts within a budget of 1.2 m, significantly less than the 1.8 m budget.
- Load floor mechanisms prototyped in 6 weeks for June review with L2 VP reviews.
Principle Engineer Seats
Lear Corporation
Southfield, US
01.2009 - 01.2013
- Lowered production tooling costs by $18.2mm by leading development of common mechanisms and structures for all three rows.
- Optimized materials to achieve 1.0 lb weight reduction on quad seat structures.
- Led interior design and engineering group on multiple projects, including DFM, CAD, CAE, and DVP.
- Project leader within group interfacing with product teams and ID groups to finalize designs for productions.
- Load floor mechanisms prototyped in 6 weeks for June review with L2 VP reviews.
- Reduced costs by $12 through elimination of inner cover snaps.
- Mentored engineering teams up 75 engineers and designers.
Global Engineering Manager Interior
Magna Steyr
Rochester Hills, US
01.2005 - 01.2009
- Managed $125M engineering projects across five locations, delivering all on schedule.
- Worked with Maserati designing new vehicle interior design with 10 engineers in Italy onsite for 2 years.
- Managed over 120 engineers and designers.
- Established operational world-class procedures, positioning two projects as role models for new facilities in Europe and ensuring alignment with OEM customer requirements.
- Designed and built high-performing teams to manage quoting for new business opportunities.
- Negotiated long term engineering agreements with key customers to support these projects, keeping exclusive relationships for up to 5 years.
- Negotiated changes to engineering contracts to enhance project outcomes.
- Reported to the Director of Engineering and Manufacturing Graz Austria Assembly division.
Engineering Supervisor - Interior Division
Ford Motor Company
Dearborn, US
01.1987 - 01.2002
- Led engineering efforts for first full plastic instrument panel production with ABS structural duct.
- Design the first full plastic IP for the F150 truck.
- Lead Engineer on new plastics products transformation from metal components to plastics like first new air induction system, fascias from metal to plastics, headlamps from metal s to plastics etc.
- Managed advanced projects in prototype shop for 5 years, supervising 50 employees across three shifts.
- Supervisor engineering design and release engineering, testing and production validation for 5 years.
- Worked as manufacturing engineer at Saline plant for 4 years, managing injection mold shop and plant operations.
- Over 20 patents on interior design, seats and consoles components also IP and door trim.
General Manager
Autodynamics Corporation
Lincoln Park, US
01.1981 - 01.1987
- Managed company interior seat structures and mechanisms, latches, and plastics from concept to manufacturing feasibility and tool sourcing.
- Developed and implemented commercial strategy for mechanisms and structures targeting non-traditional customers, enhancing market reach.
- Managed cost reduction processes for mechanisms and structures using 5S and Six Sigma methodologies, contributing over $1M to bottom line.
- Originated process to reduce raw material waste from 20% to 5% through regrind on scrap parts, improving competitive position and enhancing profits.
- Oversaw production build processes at global seat plants to ensure efficiency.
- Reported directly to Engineering Director and Vice-President of Seating Group regarding project updates.
Education
NVH MASTERS IN ENGINEERING -
UNIVERSITY OF DETROIT MERCY
Detroit, MI06-2002
BSME IN MECHANICAL ENGINEERING -
UNIVERSITY OF DETROIT MERCY
Detroit, MI05-1999
ASME IN AUTOMOTIVE DESIGN -
HENRY FORD COLLEGE
Michigan06-1982
Skills
- Cost engineering software
- Tooling expertise
- Performance metrics analysis
- Process optimization
- Cost reduction
- Cross-functional collaboration
- Effective communication
- Leadership development
- Team building
- EV battery design
- CATIA V5 and V6
- NVH expertise
- Seat design
- Budget management
- Project management
- Supply chain management
- Supplier negotiation
- Data analysis
- Problem solving
- Team collaboration
Certification
- Apriori Cost software
- NVH Masters
- Catia V6
Timeline
Head of Cost Engineering and Tooling Expert
Slate Motors
07.2023 - Current
Senior Cost Engineering Manager
Nikola Motor
11.2022 - 10.2024
Lead Cost Engineer and Tooling Expert
Rivian Automotive
06.2020 - 12.2022
General Manager R & D
Gecom Corporation
01.2020 - 06.2020
Lead Engineer Interiors & Exteriors
Waymo LLC (Google Self Driving Project)
03.2016 - 02.2020
Lead Principal Engineer
GM Interiors
01.2015 - 01.2016
Project Chief Engineer Interior
Chrysler Fiat Automobiles
01.2013 - 01.2015
Principle Engineer Seats
Lear Corporation
01.2009 - 01.2013
Global Engineering Manager Interior
Magna Steyr
01.2005 - 01.2009
Engineering Supervisor - Interior Division
Ford Motor Company
01.1987 - 01.2002
General Manager
Autodynamics Corporation
01.1981 - 01.1987
NVH MASTERS IN ENGINEERING -
UNIVERSITY OF DETROIT MERCY
BSME IN MECHANICAL ENGINEERING -
UNIVERSITY OF DETROIT MERCY
ASME IN AUTOMOTIVE DESIGN -
HENRY FORD COLLEGE