Sr VP Quality / VP Engineering Lohbauer resume

1. DA VID LO H B A U ER
11009 W 168th St. | Orland Park, IL 60467 | 847-414-1423 | dlohbauer@aol.com
Global Executive
Global business leader with a diversified background in Engineering, Quality, Operations, and Project Management.
Skilledinworkingwithglobal brandsacross differentindustries includingWeber,Motorola, and Caterpillar. Practiced in
working in progressive executive roles to lead design, manufacturing, engineering, project management, and quality
teams. Adept in leading multi-site, collaborative functions. Within different disciplines and industries. Able to offer
companies a broad experiential base to grow their operations in partnership with global suppliers, manufacturing
parties, and other essential stakeholders. Targeting Manufacturing Operations, Engineering, Quality and Project
managementrolesthatwill allowforuse of my diverse backgroundindeveloping organizations, boosting efficiencies,
improving processes, developing new products and expanding international reach.
Core Skills
QualitySystemManagement|LeanSix SigmaManufacturing|ContinuousImprovement | Manufacturing Engineering |
CapacityPlanning|ToolingEngineering|PackagingEngineering|ProductDesign|Cross-Functional Team Leadership |
CustomerService |ProjectManagement|NPIProcess|Operations Coordination| CapXProjects|ROI | Tooling&
PackagingDesign |Coatingprocess | NewProductDevelopment|ChangeControl |MasterData | DocumentControl
MS Office | SAP | AutoCAD | SolidWorks | Tooling Simulation
Proven Record of Achievement
Growth & Profitability: Designed and managed implementation of major CapX programs to eliminate capacity
constraints resulting in 30% - 100% increase in production capacity. Engineered global expansion of manufacturing
operations in China to support global growth and increase manufacturing footprint for 5 product lines building 7 base
models.
Operational Excellence: Implemented Lean Six Sigma methodologies to improve efficiency and develop internal
organizational capabilities to resolve complex problems resulting in manufacturing efficiencies exceeding 98%.
Restructured and developed organizations through internal programs to fill difficult to hire skill positions. Initiated
ProjectManagementgate release New Product Development process to ensure all product deliverables are met. Re-
designed 6internal processesincluding change control, PPAP, ICAR, NCR, master data, and document control functions
to improve process efficiencies.
Global Leadership Presence: Initiated a global quality management compliance system, global manufacturing
engineering operations, and global Project Management product rollouts. Led global quality teams, suppliers,
manufacturing introductions, and field implementations.
Accomplishments
Manufacturing Engineering:
Drove the designandimplementationof new leanautomatedmanufacturingfacilities,including
fabrication, powdercoating,andassemblyoperations insupportof new productreleases. Grew &
developedamature engineeringorganizationtosupportoperational requirementsinternallyincluding
automation,tool design,packagingandTool & Die functions. Defined capacityplanningmodelsto
identify manufacturingconstraintsbasedonproductionforecast, andimplemented multimilliondollar
CapXprograms to eliminatethem. Continuousimprovementeffortsyieldedsignificantprocess
improvementsforchange control,documentcontrol,NPI,masterdata,NCR,and PPAPfunctions.
 Increased production rates for Genesis and Summit lines by 100% through implementation of
automation, improved ergonomics, and improvements in line flow.

2. DavidLohbauer ______________Page 2
 In order to support the growing internal demand for new T & D builders, we implemented an
internal apprentice program in association with TMA
 Increasedproductionrate forQ products by 40% through implementation of internally designed &
built assembly automation. In order to support increased volumes we proportionately increased
tooling efficiency and line speed for powder coat operations.
 Increased Charcoal capacity by 30% through the addition of a 3rd
draw line, increasing furnace
capacity,and improvementsinpowdercoatefficienciesincludingroboticreinforcement developed
in house.
 Integrated the change control process from a manual to an automated work flow within SAP to
reduce cycle time and improve accuracy.
 Improvedpackagingconcealeddamage throughdesignof productstoexceedISTA designstandards.
Quality Management:
Implemented a global quality system supporting all manufacturing operations and global customer service
organizations with KPI’s to drive performance. Enhanced internal global lab capabilities in US and China to
support the new product development process, ISO compliance, PPAP, and ALT testing. Led global customer
service organizations to identify and address critical product field metrics.
 Corporate COQ reducedby50% throughreductionsinglobal fieldclaims, improvements in internal
quality and appraisal costs.
 Genesis, Spirit, Q, and Charcoal product line field failure rates below 0.5% through the analysis of
fieldreturnsandimplementationof internal quality systems. Measureable improvements seen in
damage, missing parts, corrosion claims, and thermal events.
 Manufacturing FPY for most operations exceeded 98% as a result of monthly QSR meetings. ICAR
process implemented to address nonconforming internal processes.
 Supplierqualityforall incomingmaterialsimproved over 80% to 1000 PPM. This was a result of the
implementation of SCAR process & QIP meetings with suppliers that did not meet quality targets.
 Dock to Stock initiative improved 95% for purchased components that meet requirements.
 PPAP on new products increase from less than 10% to 100%, and internal lab facilities capacity
increasedtosupportthe workload. DevelopedISOcompliance between lab facilities in the US and
China
 Managed the Document control function for internal and external specifications.
o Daily internal audits performed to ensure controlled specifications are followed, and
systems are operating within defined SPC control limits.
o As a result there have been no findings from external supplier and regulatory audits.
DevelopmentEngineering:
Managed multidiscipline design teams for new product development from concept to production release of
mobile phones and linear power amplifier base station equipment.
 Led the Mechanical Engineering development for the first Linear Power Amplifier program
 Led cross functional Mechanical and Electrical development of the next generation Expandable
Linear Power Amplifier program that reduced footprint by 30%
 Ledthe Mechanical designeffortforthe first mobile handset to use a blue LED display and joystick
control function
 Led a cross functional Mechanical and Electrical team in conjunction with a 3rd
party government
contractor to provide secure communication of the base mobile platform.
Project Management:
 Recipientof the 1998 CEO QualityAwardforProject Managementforconsistentlymeeting
projectgoalson schedule andonbudget.

3. DavidLohbauer _______Page 3
Professional Experience
Weber Stephen Products LLC. - Palatine, IL 2002 － 2016
Sr. VP of Quality
 Responsible for the global quality for this premium brand. This included supplier quality,
manufacturing quality, engineering quality, lab facilities, field quality, document control, and
product return functions.
 Helpedthe companygrowglobally throughimplementationof consistentglobal qualitysystems.
 Led the Quality organization in support of global operations and customer support.
 Improved KPI goals in all categories including supplier quality, manufacturing quality, and
product field performance.
VP Manufacturing Engineering
 Responsible formanufacturingengineering,tool &die,stampingdie,diecasting,injection mold
tool design,fixturedesign, paint and coating development, project management, engineering
change control, Master Data, Packaging design, and lab facilities.
 Developed the engineering organization to have the capability to design and implement lean
automated manufacturing facilities to meet new product development and capacity
requirements.
Motorola - Arlington Heights / Libertyville, IL 1984 － 2002
EngineeringManager
 Directed the efforts of multi-discipline engineering teams for new product development
includingdesign,analysis,andqualificationtomeetall reliability, regulatory and manufacturing
compliance requirements.
 Products developed included Mobile handsets, and linear power amplifiers.
Quality Manager
 Managed the overall quality system for 3 manufacturing facilities.
 Directed the activities of a team of quality engineers and technicians in FQA, reliability
engineering, quality process, black belt program, new product release process, and outsource
supplier quality.
Project Manager
 Directed the project management team responsible for all Linear Power Amplifier programs
including the introduction of new products into manufacturing.
 Actedas primaryliaisonbetweenCustomer,DevelopmentEngineering, and Manufacturing on a
global basis,andledeffortsforfieldimplementationof base stationequipment; includedonsite
field management of engineering teams in Japan to complete installation of new systems.
Caterpillar Tractor - Aurora, IL 1980 － 1984
DesignEngineer
 Responsible for structural analysis, design, manufacturing, and field support of rollover
protective structures, loader frames, and lift arm assemblies for track type tractors and large
wheel loader programs.
 Designedhydrauliccontrols,developedsystemsimulationmodels,andvalidatedthroughtesting
Education & Credentials
University of Illinois Champaign IL, Bachelor of Science in Mechanical Engineering
Completed Caterpillar Co-op training program while completing my degree
Member of Tau Beta Pi Honor Society University of Illinois