Bryan Joseph Zettel Date of Birth: 2nd August 1960
Personal Statement A dependable, goal oriented & hands-on engineering team member. Passionate about the quality of work I'm tasked with. Have a combination of experiences in Mechanical Engineering, Manufacturing Engineering, Facility Engineering, Project Management, Maintenance Manager & Paint Line Manager for small and large corporations (Pumping Systems Inc., GM, ABB and Magna International). Also have owned and operated an Industrial Paint and Fluid Handling Distributorship Business for 8 years. Skills PPAP Submissions APQP Design FMEA Process FMEA DOEs Auto CAD Inventor 3D Catia downloads to view and access part drawings Spinfire Viewing Web-X Conferences TS 16949 Core Tools Certification TS9001 Certification TS9000 Certification PPS (Practical Problem Solution Process) Ergonomic Design Six Sigma, Green Belt Certification Manufacturing Engineering Mechanical Engineering Facility Engineering Construction Project Management Several Years of Exterior Trim Program Launches Paint Line Manager Maintenance Manager Project Management 5s System User X-Rite Color Training Auto Vision Systems Confined Space Certification Six Axis Robot Programming (ABB, Fanuc & Motoman) Industrial Ventilation & HVAC System Design Welding (Mig, Tig, Stick & Brazing) Machining (Vertical Milling, Lathe & Finish Grinder) Paint Application Equipment System Design Paint Circulation System Design Fluid Handling System Designs for Sealants & Adhesives Plural Component Mixing System Design Sales Engineer
Computer Experience Ive been using a computer since 1976. I was taught on the old DOS Format. Ive been using a computer for work since 1978.
Software Experience Advanced in all Microsoft software applications (MS Project, Word, Excel, Power Point, Access, Publisher & Outlook) Auto CAD User (Advanced) Auto Cad Inventor (Intermediate) Maximo Maintenance Software User (Advanced) Catia Software User (Intermediate) Crystal Reports User (Basic) Spinfire Viewer Primavera Project software Maximo Maintenance and Facility software Empower Purchasing software Allen Bradley PLC software PPS software Mini-tab software for Six Sigma Projects Lotus Notes
Education and Certificates June 25, 2009 Magna Corporate Training, Boyne City, Mi. Phased AQP Process June 02, 2009 Magna Corporate Training, Boyne City, Mi. (PPS)Practical Problem Solving System May 16, 2009 Omnex, Boyne City, Mi. TS16949 Core Tools Training April 09, 2008 Magna Corporate Training, Boyne City, Mi. Lean Manufacturing September 12 13, 2007 Magna Corporate Training, Boyne City, Mi. Ergonomics in Engineering Design May 20 May 21, 2006 AIAG, Southfield, Mi. FMEA Third Edition Training May 18 May 19, 2006 GM Tech Center, Warren, Mi. GM Global Part Submission Procedure for Dimensional Fit, Function and Appearance April 20 April 21, 2006 AIAG, Southfield, Mi. PPAP Fourth Edition Training May 18 May 24, 2004 North Central Michigan College, Petoskey, Mi. Lean Manufacturing II (2 Credits) February 26 May 20, 2004 Magna Certified Master Black Belt Trainer, Boyne City, Mi. Green Belt Training Green Belt Certification May 09 May 10, 2003 North Central Michigan College, Petoskey, Mi. Six Sigma Champion Training June 19 June 24, 2000 North Central Michigan College, Petoskey, Mi. Lean Manufacturing I (2 Credits) June 07 08, 2000 Decoma ESE Corporate Training Catia Station Training to view and download Part Drawings for Chrysler Part Designs May 09 June 01, 2000 North Central Michigan College, Petoskey, Mi. Hydraulics and Pneumatics System Design & Controls (4 Credits) September, 1999 North Central Michigan College, Petoskey, Mi. Automation Controls (2 Credits) March 11 March 12, 1999 SAE Training Course in Rochester Hills, Mi. Finishing System Design (2 Credits) January 20, 1999 North Central Michigan College, Petoskey, Mi. Process Flow Jan 08, 1996 - Jan 19, 1996 Michigan State University Industrial Ventilation and HVAC (4 Credits) Nov 1987 Baker College Small Business Course (4 Credits Oct, 1987 U of M Flint Managing & Financing a Small Business (2 Credits) Jan 07, 1980 - May 30, 1980 Genesee Area Skill Center / Mott Community College MACHINIST I & II (4 Credits) Jan 07, 1980 - May 30, 1980 Genesee Area Skill Center / Mott Community College Welding I & II (4 Credits) Employment History Several Engineering and Management Positions over 11+ Years Employed by LexaMar Corporation a Division of Magna International located in Boyne City, Mi. Detailed below; Employed June 1998 Sept 2009 March 2009 Sept 2009 Paint Line Business Unit Manager Nov 2008 -Mar 2009 Special Project Engineer Relocated Six TPO Exterior Part Programs from three Magna Plants that were being shutdown and brought into the LexaMar Facility
LexaMar continued Aug 2008 Nov 2008 Special Project Engineer Consolidated 3 local Plants into one. Part of a Corporate Restructuring Nov 2004 Aug 2008 Manufacturing Engineer Responsibilities were DFMEAs, PFMEAs, DVP&Rs, Part Design reviews, Tooling, Secondary Equipment, Assembly Equipment, Gages, Tool Trials, Gage R&Rs, Part Gauging after Molding, after Paint and Assembled for dimensional studies. Highlight: Developed LexaMars first Semi-Automated Acrylic Tape Assembly System for DCX KA Body Side Moldings. Project Managed from Concept, Scope of Work, Engineering, Fabrication, Assembly, and Start-up & Debug. Highlight: Installed Robotic Router to remove hang tabs on the Polycarbonate and SMC C6 Vette Moon Roofs. Highlight: Installed Robotic Clip Installation System for the Ford F150 Wheel Flares. Highlight: Installed Robotic Router System to remove material on Ford Explorer Polycarbonate Appliqus W/Keyless Entry. Highlight: Made a difference by bringing in several Automated Assembly Processes into Production for LexaMar Nov 02 Nov 04 Facility Engineer Highlights: Upgraded and Installed an Auto Temperature Zone Controlled Air/Heat Controls for Front Offices, Quality Offices and the Engineering Offices. (Energy Savings) Hired a HVAC Technician and set-up a PM Plan for 47 AHUs throughout the plant. Jun 18, 2001 -Nov 25, 2002 Project Managed a Hard Coating System & a 50K Building Addition Highlight: Made a difference by utilizing my past work experiences and skills to assist LexaMar in a ground up major Capital Project that came in over budget. We convinced Corporate Magna to allow LexaMar to self perform this new Hard Coat Process System to be within the payback budget, this would also include the 50K Building to house it. LexaMar Management assigned me to General Contract a Design & Build 50K Building and Hard Coat Process System. This was a major project for LexaMar with a total budget of $8.3 Million. This Project was Designed, Contracted and Built in Budget and on Time for Production. This project included the following equipment; 9) Air Handling units equipped with cooling coils, 2) stage filtration & VFDs, two 30,000 CFM Rapid 80/20 Volumetric Air Make-up units, 4) Heater Boxes & 2) Des-Champ Dehumidification units for the coating line. The Building addition required a new site plan to include a new 450 space parking lot & lighting, new underground drain system, retention ponds, landscaping, 1500GPM Fire Pump House & a new 5000KVa underground electrical source. Inside the building required 11 new offices, fire protection, lighting, HVAC, 2) 300 Ton Chillers. This was one of the most rewarding Projects I've been assigned to date. We saved the Company $4 Million self performing this project. Oct 09, 2000 -Jun 15, 2001 Maintenance/Facility Manager Highlights: Made a difference by purchasing and implementing a Maximo Software Maintenance Process System. Brought the Maintenance and Facility Team to the next level (98% Machine Uptime). May 08, 2000 - Oct 06, 2000 Facility Supervisor Highlight: Made a difference by organizing a Facility Team and setting up a PM Plan and Schedule. LexaMar continued June 18, 1998 -May 05, 2000 Facility Engineer Highlights: Made a difference by Saving the Company Millions of dollars by self performing major capital projects listed below; Upgraded (14) Rooftop AHUs to Temperature Control & Positive Pressurize the Plant. (Energy Savings) Built LexaMars first Paint Kitchen and Installed a 22 Paint Circulation System to all Six Paint Booths. Built a Utility Room to consolidate the Compressed Air Compressors, Compressed Air Dryers, Process Chillers and Cooling Towers. (Gained 12,000 square feet of production area) Installed (5) new ABB 510 Flexi Wrist Paint Robots. This was LexaMars first Six Axis Robots. (Production Gains and reduction of 10 Painters) Installed (2) new 200 HP Compressors one was Variable Speed and acted as a trim compressor it had a 6 month pay back on energy savings. LexaMar continued Project managed a two week shutdown project replacing the existing six paint booths and re-installing five new recirculation booths. (Increase in paint line capacity). Upgraded All Plant Lighting to more efficient HID Lighting. (Energy Savings) Employer Contact Breen Merriam HR Manager Phone:(231)348-9242 Email:breen_merriam[at]magna.com Work History at LexaMar Corporation a Division of Magna International Started June 1998 Sep 2009 I made a family decision to enter the Plant Life so I could be with my young kids during their critical years. Recently I have been laid off due to the economic downturn in the Automotive Industry. I enjoyed my 11+ years of employment at LexaMar it was a great place to work, I gained allot of experience, training and lifelong friendships.
Senior Mechanical Engineer / ABB Paint Finishing in Auburn Hills, Mi. March 1996 June 1998 Worked in many aspects of the business including; Mechanical Engineering, Project Manager and Sales Engineer. Responsibilities were to engineer, design & size Air Houses for large Paint Systems Projects, fans for Paint Booths, Ovens & Washers and Paint Circulation Systems. Projects include; Project Manager for JNAP Model Changeover Shutdown Job Project Manage Paint Circulation and Paint Application System for Navistar Monterey, Mexico oHighlight: First self performed Paint Circulation System by ABB Paint Finishing. Project Manage Paint Circulation and Paint Application System for Volvo Truck in Curitiba, Brazil Sales, Engineer and Project Manage LexaMar Corp. D2 Hard Coat System. oHighlight: Sold to my old Tier 1 Customers for the ABB Industrial Sales Team Sales, Engineer and Project Manage LexaMars ABB Pre-heater RTO. Sales, Engineer and Project Manage Peregrine Interior Door Panel Glue Line. Project Engineer for Bodine Aluminium installing a Fume Scrubber from ABB Japan. Project Engineer for ABB T&D installing an Industrial Painting System for Large Transformer. Project Engineer for the EV1 Electric Vehicle [at] the GM Lansing Craft Center. Worked on trouble shooting the Cure Oven. It was a tough decision to leave ABB Paint Finishing and the travel opportunities, training and friendships established. If this would have been a different time of my life when my kids were grown up, I wouldnt have left.
Level III Contract Mechanical Engineer for General Motors Flint, Mi. Plant #2 thru Unique Creations Inc. in Fenton, Mi. Sep 01, 1994 - Mar 01, 1996 Working Owner This GM Plant was a Parts Supplier to GM Truck in Flint, Mi., Fort Wayne, Indiana & Oshawa, Wisconsin. I started as supplying Graco Industrial Paint Application Equipment to this GM Plant in Flint, Mi., they were having major Quality issues and on 3rd Party Containment. I negotiated an Engineering Contract for their G-Van Grille Paint Process. After improving this process they approached me to extend this Engineering Contract to assist in their new GMT 600 Grille Paint Line. Projects Include; Upgraded the G-Van Paint Process, wrote a PFMEA and removed the plant off 3rd Party Containment. Part of an Engineering Team that self performed a Design and Built a World Class Paint System for the GMT 600 Truck Grilles, utilizing the GM Skilled Trades. GM continued oHighlight; Awesome experience for me. Installed an Automated Masking System for the GMT 600 Truck Grill. oHighlight; Awesome experience for me. Installed All the Graco P-Mix a 2 Component Paint Mixing System. Worked with ABB Robots to Install (8) 5001 Paint Robots. oHighlight; Awesome experience for me. Installed all the Paint Circulation Systems. Launched the GMT 600 Chevy Chromed ABS Grille, GMC Painted TPO Grille & the Chevy Painted TPU Work Truck Grille GM continued Left GM only because they were cutting back on Contract Engineers after the Paint System was up and running production. Almost went to work as a full time GM Employee for the NAO Paint Group in Warren, Mi. The ABB Technician assigned to this GM Project told me about openings at ABB so I applied and was hired.
Sales Manager/President of Pumping Systems Inc. Owosso, Michigan Oct 1987 - March 1995 Purchased the Company I've been working for (Pumping Systems Inc.), the previous owner and I negotiated a win win contract that gave him a nice yearly retirement income and kept the Companies Cash flow intact. The Company bought the Company. Pumping Systems was an Industrial Distributor for Graco, Binks, Devillibis Fluid Handling of Paint, Adhesives, Mastics and Paint Spray Application Equipment. Six months into the Engineering Contract above with General Motors I came to a cross road in my work career and personal life my family and I decided to sell off the assets and close down Pumping Systems. Highlight; The Companies Annual sales prior to the purchase was $750K. Within the first year we increased the sales to $1.2 Million. By the final year we had annual sales of 2.1 Million in tough Michigan Economic times. Average Annual Net income was 13.4% Highlight; after the purchase we picked up Nordson Powder Coating, Graco Robotics, JBI Paint Booths and Pyles Pumps.
Sales Engineer Pumping Systems Inc. Owosso, Mi. Feb 06, 1984 - Oct 12, 1987 I was approached by the Graco Industrial Regional Manager for Michigan to join Pumping Systems Inc. as a Sales Engineer. Highlight; Made a difference by growing a Northern Michigan Territory from $50K Annually in Sales to $450K annually in 3.5 years. Pumping Systems was an Industrial Distributor for Graco, Binks, Devillibis Fluid Handling of Paint, Adhesives, Mastics and Paint Spray Application Equipment. Accounts Like Taylor Door, Dow Corning, Dow Chemical, LexaMar Corp., Weyerhaeuser, Champion Homes, Saginaw Steering Gear, Besser Corp., Magline and etc.
References: Larry McQuiggWork Associate / GM Flint Mobile:810-236-0363 Mike SevernChrysler/DCX/Chrysler Program Manager / LexaMar Corporation Mobile: 231-313-7744 Craig MontieDCX/Chrysler SQE for the KA Body Side Moldings Work: 248-379-1009 Joe AudiaPlant Manager / LexaMar Corporation Mobile:231-838-1332 Jeff DemingPurchasing Manager / LexaMar Corporation Mobile:231-675-8267 Scott Gignlette Engineering Manager / LexaMar Corporation Mobile:231-675-1260 Dana DickService Technician / ABB Flexible Automation Mobile:248-670-0681
Hobbies & Other Interests I enjoy the following; Boating, Downhill Snow Skiing (Currently on a GS Race League), Golfing (Currently on a League), ATV Trips, Snowmobiling, Hunting Pheasant & Deer, Shooting & Travelling.
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