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1 7 4 9 N o r t h w o o d • T r o y , M i c h i g a n 4 8 0 8 4 T e l : 2 4 8 - 3 6 2 - 5 1 1 0 F a x : 2 4 8 - 3 6 2 - 5 1 1 7
Lean Design® is a registered trademark of Munro & Associates, Inc. 1
Table of Contents
SUSAN OKRAY ...................................................................................................................................... 3 Specialized Professional Competence .................................................................................................. 3
Background and Professional Honors ................................................................................................... 3 JOHN BOYLE .......................................................................................................................................... 4
Specialized Professional Competence .................................................................................................. 4 Background and Professional Honors ................................................................................................... 4
ALBERT STEIER .................................................................................................................................... 5
Specialized Professional Competence .................................................................................................. 5
Background and Professional Honors ................................................................................................... 5 THOMAS SHORT.................................................................................................................................... 6
Specialized Professional Competence .................................................................................................. 6
Background and Professional Honors ................................................................................................... 6 WILLIAM SPRAGUE.............................................................................................................................. 7
Specialized Professional Competence .................................................................................................. 7 Background and Professional Honors ................................................................................................... 7
MICHAEL DONOGHUE ......................................................................................................................... 8
Specialized Professional Competence .................................................................................................. 8 Background and Professional Honors ................................................................................................... 8
JAMES BLOCKER .................................................................................................................................. 9 Specialized Professional Competence .................................................................................................. 9
Background and Professional Honors ................................................................................................... 9 RAYMOND GAGE III ........................................................................................................................... 10
Specialized Professional Competence ................................................................................................ 10 Background and Professional Honors ................................................................................................. 10
DAVID OBERHOLTZER ...................................................................................................................... 11
Specialized Professional Competence ................................................................................................ 11 Background and Professional Honors ................................................................................................. 11
TIM SHAW ............................................................................................................................................ 12 Specialized Professional Competence ................................................................................................ 12 Background and Professional Honors ................................................................................................. 12
CHRIS FERLAND ................................................................................................................................. 13 Specialized Professional Competence ................................................................................................ 13
Background and Professional Honors ................................................................................................. 13
MARTY KOWALSKY .......................................................................................................................... 14
Specialized Professional competence ................................................................................................. 14 Background and Professional Honors ................................................................................................. 14
DAVID WARNER ................................................................................................................................. 15 Specialized Professional Competence ................................................................................................ 15 Background and Professional Honors ................................................................................................. 15
1 7 4 9 N o r t h w o o d • T r o y , M i c h i g a n 4 8 0 8 4 T e l : 2 4 8 - 3 6 2 - 5 1 1 0 F a x : 2 4 8 - 3 6 2 - 5 1 1 7
Lean Design® is a registered trademark of Munro & Associates, Inc. 2
CORY STEUBEN .................................................................................................................................. 16 Specialized Professional Competence ................................................................................................ 16
Background and Professional Honors ................................................................................................. 16 CHRISTOPHER FOX ............................................................................................................................ 17
Specialized Professional Competence ................................................................................................ 17 Background and Professional Honors ................................................................................................. 17
JAMES HADLEY .................................................................................................................................. 18
Specialized Professional Competence ................................................................................................ 18 Background and Professional Honors ................................................................................................. 18
MARK FAZI ........................................................................................................................................... 19 Specialized Professional Competence ................................................................................................ 19 Background and Professional Honors ................................................................................................. 19
STEPHEN JU.......................................................................................................................................... 20 Specialized Professional Competence ................................................................................................ 20
Background and Professional Honors ................................................................................................. 20 GREG JONES ......................................................................................................................................... 21
Specialized Professional Competence ................................................................................................ 21 Background and Professional Honors ................................................................................................. 21
DANIEL MCCARTHY .......................................................................................................................... 22 Specialized Professional Competence ................................................................................................ 22
Background and Professional Honors ................................................................................................. 22 WILL SULLIVAN.................................................................................................................................. 23
Specialized Professional Competence ................................................................................................ 23
Background and Professional Honors ................................................................................................. 23 SANDY MUNRO ................................................................................................................................... 24
Specialized Professional Competence ................................................................................................ 24
Background and Professional Honors ................................................................................................. 25
1 7 4 9 N o r t h w o o d • T r o y , M i c h i g a n 4 8 0 8 4 T e l : 2 4 8 - 3 6 2 - 5 1 1 0 F a x : 2 4 8 - 3 6 2 - 5 1 1 7
Lean Design® is a registered trademark of Munro & Associates, Inc. 3
SUSAN OKRAY
Specialized Professional Competence Expertise resides in product engineering, product cost reduction, quality enhancement and lead time reduction
through the strategic adoption and implementation of concurrent engineering practices. Over twenty years of
experience in competitive benchmarking, plastics and interior product and systems engineering, program
coordination and management, quote/cost evaluation and new product development. Automotive OEM interior
trim design, engineering and assembly plant launch experience. Received special recognition for improving
interior quality ratings for the Camaro/ Firebird, presented to the top 18 executives at GM. Directed product
engineering teams assigned to current and future OEM automotive programs. Management of a staff of
technical and senior engineers supporting new program quote packages on automotive interior trim
commodities. Responsible for employee performance reviews, annual budgets and allocations, project
assignments, quote packages, quote presentations, engineering reviews, tool investment budgets, tool reviews,
including APQP (Advanced Product Quality Planning and Control Plan) and PPAP (production part approval
process) elements. Management of a competitive benchmarking group responsible for OEM and supplier
corporate cost-down activities, including Lean Design consulting, reverse engineering, benchmarking, cost
analysis and data collection resulting in yearly increases in productivity and product quality.
Background and Professional Honors Benchmarking Director (2000- Present)
Munro & Associates, Inc.
Applications and Engineering Manager (1997 – 2000)
United Technologies Automotive
Product Cost Engineering Manager (1995 - 1997)
Xerox Corporation
Product Engineer (1984 - 1995)
General Motors
Co-op Student (1980- 1984)
General Motors
DEMS, Doctorate of Engineering in Manufacturing Systems, 2008
MEMS, Masters of Engineering in Manufacturing Systems, 2002
MBA, University of Michigan, 1991
BSME, Bachelors, Mechanical Engineering, Kettering University, 1984
Graduated with Honors
Tau Beta Pi (National Engineering Honor Society)
Member- Society of Manufacturing Engineers and American Society of Automotive Engineers
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Lean Design® is a registered trademark of Munro & Associates, Inc. 4
JOHN BOYLE
Specialized Professional Competence
Expertise resides in product engineering, product cost reduction, quality enhancement and lead time reduction
through the strategic adoption and implementation of concurrent engineering practices. Nearly twenty years of
experience in competitive benchmarking, design for assembly, program management, cost reduction and
workplace ergonomics.
As a Certified Professional Ergonomist (CPE), managed a staff of technical and senior engineers supporting new
program launches for (4) different product programs. Responsible for employee performance reviews, annual
budgets and allocations, project assignments.
As an Industrial Engineering Specialist, led the restructuring of OEM teardown processes to be fully integrated
into OEM product development process reducing manpower requirements, increasing throughput and idea
implementation rates. Facilitated the benchmarking of (7) different complete competitive vehicles during (4)
year period, presenting to COO or VP of Engineering following the completion of each teardown.
As a consultant, disassembled and analyzed interior, exterior, and chassis systems for OEM, presenting ideas for
cost and throughput improvement. Provided Lean Design consulting, reverse engineering, benchmarking,
quality and cost analysis support for automotive, aircraft, shipbuilding, and defense industries.
As a Systems Engineer, facilitated teardowns and over (100) product improvement workshops for most major
vehicle systems in support of the 1997 Chevy Malibu, 1998 Cadillac STS, 1999 Bonneville, 2000 Cadillac
Deville.
Background and Professional Honors
Design Prophet (Engineering Consultant) (2008 - Present)
Munro & Associates, Inc.
Ergonomics Manager (2007 -2008)
Chrysler, LLC
Industrial Engineering Specialist (2004-2008)
Chrysler, LLC
Design Prophet (Engineering Consultant) (1997 - 2004)
Munro & Associates, Inc.
Engineering Systems Engineer (1990 – 1996)
Electronic Data Systems
M.Eng., Master of Engineering – Industrial Ergonomics,
University of Michigan, 1997
BSME, Bachelors, Mechanical Engineering, Worcester Polytechnic Institute, 1990
Graduated with Honors
NIOSH Fellow – University of Michigan (1997)
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Lean Design® is a registered trademark of Munro & Associates, Inc. 5
ALBERT STEIER
Specialized Professional Competence More than 25 years of hands-on automotive vehicle systems service, manufacturing and engineering experience.
Extensive expertise in the emerging principles of Lean Design® and Manufacturing. Served in the US Army
Ordinance (Automotive) Branch for 12 years, 8 of which were in Germany. Responsibilities included
supervising up to 30 personnel and managing scheduled and unscheduled maintenance of over a 100 pieces of
equipment including power generation, track and wheeled vehicles. Central Texas College Automotive
Instructor for basic electrical and advance engine service courses. Responsible for developing all labs,
assignments, tests and grading systems along with all associated administrative responsibilities.
RWD Technologies assigned to DaimlerChrysler Advanced Technical Training Department
developing and delivering courseware training on new products for plant engineering and manufacturing
personnel. Team Leader for the Vehicle Systems Specials team St Louis, Windsor and Sterling Heights
Assembly Plants. Providing on floor support for engineering and reprocess personnel, identifying training
needs and implementation, developing and delivering training, conducted root cause analysis and feedback
for resolutions.
Extensive back ground in Power Train, Electrical and Chassis systems. Providing manufactures the
means of reducing costs, weight and investment through a vast knowledge of vehicle systems and
integration. Introducing new materials and processes and cutting lead time through the strategic adoption
and implementation of concurrent engineering practices. Project leader for a 16 engine benchmarking study
capturing detailed design data, estimating component costs, identifying eye catching features and all
aspects of assembly. Project leader for various cost studies including brake calipers, suspension systems,
and engine mounts. Conducted Lean Design® Workshops, Product Analysis and Reverse Engineering for a
wide scope of clients and products including full vehicle teardowns, 16 engines, 7 transmissions, and
various suspension modules.
Background and Professional Honors Design Prophet (September 2001 – Present)
Munro & Associates, Inc.
Associate New Product Development and Delivery for engineering and plant personnel (July 1995 – September
2001)
RWD for DaimlerChrysler Corporation
Automotive Maintenance Instructor (1994 – 1995)
Central Texas College (European Brach)
Track and Wheeled Vehicle Maintenance (1983 – 1995)
Sergeant First Class, US Army
Graduate of Central Texas College (European Branch)
Extensive Professional Military Training receiving 6 certificates.
Special Recognition by Chrysler for generating a $235M euro savings powertrain cost reduction idea with a
continued $60M euro savings per year in years beyond the tracked period.
Certifications: Automotive Service Excellence Master Technician, Underbody Specialist and Advance Engine
Service Specialist.
Recent Publications Coauthor of EE Times - Under the Hood cover story May 2007: Tried-and-true design concepts drive Prius.
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Lean Design® is a registered trademark of Munro & Associates, Inc. 6
THOMAS SHORT
Specialized Professional Competence Twenty five years experience in the application of Lean Design® and design for manufacturing and assembly to
a wide range of products from automotive systems (General Motors, Ford, Chrysler, Bentley, Rover, TRW, and
Tata), to aircraft systems (DC-10, MD-11, Boeing 747 and 777, C-17) to defense applications (DRS, L3, ATK,
British Aerospace, General Dynamics) to consumer products (Cummins, Nikon, Bell&Howe, JCB, and Fuji).
Directed and conducted benchmarking, competitive studies, and part and system cost analysis on a variety of
automotive components (engines, transmissions, brake boosters, fuel pumps, steering gears, doors and front end
modules) and on numerous complete vehicles. From 1985 to 1995 trained hundreds of Ford engineers in design
for manufacturability with emphasis on part cost estimating and evaluating the costs of design changes.
Thirty five years experience in computer aided design as a consultant, speaker, author, and designer starting in
1965 with Unigraphics and currently with Autodesk’s Inventor solid modeler. Author of a series of books on
Inventor published by Goodheart-Willcox.
Background and Professional Honors Consultant 2000 – Present
Munro & Associates, Inc.
Founder & CEO 1983 - 2000
CommandTrain, Inc a Michigan corporation specializing in CAD consulting & training and in Design
for Assembly consulting and application
Unigraphics CAD consultant 1981 -1982
McDonnell Douglas Corporation
Professor of Mechanical Engineering 1963 - 1981
General Motors Institute
Group Leader, Structural Testing Lab 1960 - 1963
Ford Motor Company
Test Engineer 1959 - 1960
Chrysler Missile Division
Post Graduate, System Engineering, completed course work for PhD, Michigan State University 1970 -1975
Registered Professional Engineer (P.E.) State of Michigan, 1965 - Present
M.S. (Mechanical Engineering), Wayne State University, 1965
B.S. (Mechanical Engineering), Wayne State University, 1959
Member- Society of Automotive Engineers and Society of Manufacturing Engineers
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Lean Design® is a registered trademark of Munro & Associates, Inc. 7
WILLIAM SPRAGUE
Specialized Professional Competence Expertise resides in extensive knowledge of new product development processes to provide comprehensive
design and manufacturing engineering product enhancements, integration of development process tools, and
implementation of concurrent engineering techniques. Possesses significant analytical and costing skills utilized
to assist companies to quickly surmise the best areas to concentrate cost and quality improvement efforts. This
integration of methodologies and results has created customer products with improved time to market,
efficiency, manufacturing flow and market share performance for a wide variety of clients in automotive and
other industries. He has conducted hundreds of Lean Design® and related topic workshops, training thousands of
design and manufacturing engineers. Bill’s credentials as a pioneer in Design for Manufacturability
implementation were established at NCR Corporation for his project leadership on retail terminal and checkout
scanners using Design For Assembly, cross-functional teams, and advanced CAD/CAM tools. At the corporate
level, he drove DFM efforts to provide competitively superior products faster to market resulting in NCR being
benchmarked as an industry leader. Recognized as a global expert in the implementation of Product
Development improvements, he has spoken at over 100 conferences worldwide and has published eight papers
on Lean Design®, DFA/Concurrent Engineering Case Studies, Concurrent Engineering and DFA
Implementation, Design for Environment and Culture Change aspects for DFA. His work and views on industry
trends have been cited in numerous publications including Business Week, Design News, Industry Week, and
others. He is a recipient of the Assembly “Productivity thru Assembly Technology” Award and has been
awarded many company project and technical citations including ones from NCR, HP, and Hitachi.
Background and Professional Honors Design Prophet (Engineering Consultant) (1998 - Present)
Munro & Associates, Inc.
Senior Consultant, Product Development (1996-1998)
International TechneGroup Inc.
Vice President Training & Consulting Services (1992 - 1996)
Boothroyd Dewhurst Inc.
Manager, Corporate Manufacturing Technology (1986 - 1992)
NCR Corporation
Senior Facility Engineer (1983- 1986)
Northern Telecom
Manufacturing Engineer (1981-1983)
Schlumberger
Manufacturing/Facility Engineer (1979-1981)
Siemens-Allis Corporation
MBA, Florida Atlantic University, 1986
BSIE, Bachelors, Industrial Engineering, Purdue University, 1979
Tau Beta Pi (National Engineering Honor Society)
Senior Member- Industrial Engineering Society, Society of Automotive Engineers
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Lean Design® is a registered trademark of Munro & Associates, Inc. 8
MICHAEL DONOGHUE
Specialized Professional Competence
Extensive experience in product development consulting, engineering and manufacturing engineering,
Michael Donoghue offers clients special expertise in the consultation, facilitation, implementation, and
training of concurrent engineering principles and Design Profit methods for improvements in product
development and product design. A proven track record helping clients enhance their products and
achieve dramatic improvements in product design, cost, quality and profitability through the
application of concurrent engineering and Design Profit principles.
Consulting on an international basis for the last 13 years with companies in numerous industries,
including agricultural, automotive, defense, medical devices, semiconductor equipment, aerospace and
many others. Prior experience includes 14 years in the medical device industry in design,
manufacturing and program management roles. Holds Bachelor of Science degree in Electrical
Engineering Technology and a Master’s of Science Degree in Manufacturing Systems Engineering.
Background and Professional Honors
Design Prophet (Consultant) 2000 - Present
Munro & Associates, Inc. (Troy, MI)
CP/PD Consultant, Design For “X” Practice Leader 1996 -2000
International TechneGroup, Inc (Milford, OH)
Concurrent Engineering / DFMA Consultant 1995-1996
Donoghue Consulting, (New Kensington, PA)
Engineering & Project Leader Roles 1989 - 1996
Respironics, Inc. (Murrysville, PA)
Design, Manufacturing & Test Engineering 1982 – 1989
Dymax Corporation (Pittsburgh, PA)
M.S. (Manufacturing Systems Engineering), University of Pittsburgh, 1996
B.S. (Electrical Engineering Technology), Point Park University, 1985
Key Note Speaker at the ISID CAE Solutions Conference 2007, Tokyo, Japan
“DFMA at Respironics, Focusing on the Design Team” - Presented at the International Forum on Design for
Manufacturing and Assembly - June 1995
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Lean Design® is a registered trademark of Munro & Associates, Inc. 9
JAMES BLOCKER
Specialized Professional Competence Specialized in recognizing design opportunities and integrating different applications found in a wide
variety of products. Thirty years of hands-on work experience and technical training instruction in
technologies ranging from small air cooled engines to advanced automotive, agricultural, and heavy
construction equipment systems. Currently provides manufactures with solutions that increase quality and
reduce cost from a wide variety of product types and design strategies.
Technical training background includes developing and delivering both instructor-led and web-based product
training for service technicians, manufacturing technicians, and engineers. Clients included are; General Motors,
Chrysler, Caterpillar, Freightliner, John Deere, and Daewoo Automotive. Conducted complete hands-on training
for complete overhaul of multi-cylinder gasoline engines as well as two and four stroke diesel engines for the
United States Air Force. As a farm equipment technician, diagnosed and repaired a broad range of agricultural
equipment systems such as diesel fuel delivery, open and closed center hydraulics, air conditioning, and heavy
duty power transmission systems. Job responsibilities included complete overhaul of gasoline and diesel engines
as well as servicing and adjusting all types of harvesting, tillage, and planting equipment.
Background and Professional Honors Benchmarking Associate (2006- Present)
Munro & Associates, Inc.
Technical Training Instructor/Developer (2003 – 2006)
Raytheon Professional Services
Technical Training Instructor/Developer (1998 - 2003)
RWD Technologies
Master Technical Training Instructor (1988 - 1998)
United States Air Force
Agricultural Equipment Technician (1978- 1988)
Kavalier Implement Inc.
Associates, Automotive Vehicle Technology, Community College of the Air Force, 1994
Associates, Technical Training Development, Community College of the Air Force, 1995
Master Automotive Service Excellence Certified, 2004
Automotive Service Excellence Certified, 1990
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Lean Design® is a registered trademark of Munro & Associates, Inc. 10
RAYMOND GAGE III
Specialized Professional Competence Successfully completed three cooperative assignments with General Motors in a two year period in vehicle
design, validation, and manufacturing. Project and work responsibilities included: re-engineering and designing
crash test fixture mounting systems. Producing computer generated build drawings for fabrication technicians.
Designing and leading fabrication, installation, and re-certification of moving crash barrier re-ballast project to
conform barrier to federal regulations. Carrying out, completing, and submitting Red-X Apprentice and
Journeyman level quality investigation projects in vehicle quality control trails and process refinements.
Creating database for all 2006 Competitive Tire Benchmarking test and effectively analyzing Tire
Benchmarking data. Performing tire bead seat testing, analysis, spring rate, tread depth, and low speed
uniformity tire testing.
Successfully completed three internship assignments with General Motors in a three year period in vehicle
design and validation. Project and work responsibilities included: developing and testing a concept diesel fuel
cooler for an engineering cost-savings project. Examining and analyzing possible full size truck fuel system
warranty quality control issues. Analyzing the integrity of vehicle air induction designs to water intrusion.
Preparing vehicles, performing testing, collecting and analyzing data, reporting results and conclusions. Setting
up and running testing on five different vehicle platforms to examine material fatigue properties.
Background and Professional Honors Vehicle Safety & Crashworthiness Laboratory Engineer (2008)
General Motors, Milford Michigan
Vehicle Assembly Engineer (2008)
General Motors, Mishawaka Indiana
Tire and Wheel Systems Group Engineer (2007)
General Motors, Milford Michigan
Full Size Truck Fuel System Engineer (2006)
General Motors, Warren Michigan
Vehicle Water Intrusion (2005)
General Motors, Milford Michigan
Vehicle Performance Center Testing Assistant (2004)
General Motors, Warren Michigan
Masters, Mechanical Engineering, University of Detroit Mercy, 2010
Bachelors, Mechanical Engineering, University of Detroit Mercy, 2009
Successful completion of the Fundamentals of Engineering Exam, June 2009
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Lean Design® is a registered trademark of Munro & Associates, Inc. 11
DAVID OBERHOLTZER
Specialized Professional Competence Thirty years of experience in product design, manufacturing, and in productivity improvement. Recent projects
identified and implemented improvements in the Future Combat Systems (FCS) vehicles and other defense systems,
Tata Nano small car, BA 609 Tiltrotor aircraft, factory batch processing equipment and product flow, trucking
hardware, oil filters, power brake boosters, and fuel pumps. Dave is a Six Sigma Master Black Belt. Dave conducted
an analysis of the Stryker Mobile Gun System that identified improvement opportunities in cost and reliability. Dave
analyzed warranty data for a fuel pump manufacturer which highlighted manufacturing process problems. This led to
identification of the true root causes and to an overall reduction of warranty costs. Dave was one of the Munro team
that analyzed the Tata Nano design and identified several cost saving opportunities that helped Tata achieve its goal
of designing a $2500 car. Dave led a project for a trucking hardware firm and developed an innovative, patent-
pending solution to reduce weight and cost while improving reliability. As a Principal Systems Engineer at Raytheon
Dave championed Design for Six Sigma and worked on a variety of high profile programs such as Global Hawk,
Paveway Laser Guided Bomb, HARM (High-speed Anti-Radiation Missile), Tank Thermal Sights, FLIR (Forward
Looking Infra-Red) Common Modules, and anti-ballistic missile defense. With a strong background in factory
automation and systems analysis, Dave was instrumental in Texas Instruments winning the CASA/SME LEAD
Award for Computer Integrated Manufacturing in 1987 and led a team of engineers and technicians that supported the
integrated factory systems. Dave was also part of the core team that deployed six sigma at Texas Instruments (TI).
This was cited as one of the key reasons for TI winning the Malcolm Baldrige National Quality Award in 1992.
Dave’s insight into the applicability of engineering practices to software development helped TI achieve its SEI
CMM goals.
Background and Professional Honors Design Prophet (2006 - Present)
Munro & Associates, Inc.
Principal Systems Engineer (2004 – 2006)
Raytheon Company
Raytheon Six Sigma Expert (1998 – 2006)
Raytheon Company
Six Sigma Black Belt / Master Instructor (1992 – 1997)
Texas Instruments
Systems Supervisor/Manager (1986 - 1992)
Texas Instruments
Manufacturing Engineer / Production Control Supervisor (1979 – 1985)
Texas Instruments
Field Artillery Officer (1974 – 1979)
US Army
MBA, Amber University, 1985
BSME, Bachelors, Mechanical Engineering, Rose-Hulman Institute of Technology, 1974
US Army – Ranger, Master Parachutist, FAOBC Honor Graduate, EINPAC Distinguished Graduate
Member - Society of Manufacturing Engineers, American Society for Quality, International Society of
Six Sigma Professionals
Bilingual in English and Italian
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Lean Design® is a registered trademark of Munro & Associates, Inc. 12
TIM SHAW
Specialized Professional Competence Expertise resides in lean manufacturing, automation design, process design, process and equipment
improvement.
As a consultant, led kaizen activities resulting in improved product, material and information flow throughout
the entire process including sub-suppliers. Kaizen activities have been conducted in many different industries
including; defense, automotive, paper handling, mold manufacturing and confectionary products.
As an Advanced Manufacturing Engineer, designed equipment, wrote technical process specifications, procured
automation equipment, oversaw equipment installation, trained maintenance and operator personnel and wrote
process documentation. Responsibilities included managing a staff of manufacturing engineers responsible for
equipment design commonality, equipment cost, overall project timing, ROI, direct and indirect headcount and
operating costs.
As a Manufacturing Engineer, oversaw improvement projects for multiple product assembly lines.
Improvement projects included; increasing “Overall Equipment Efficiency" (OEE), headcount reduction through
process improvement activities and purchasing automation equipment, scrap reduction, and increased “First
Time Through” (FTT).
As an Automation Design & Build Specialist, oversaw the build and installation process for highly automated
equipment. Responsibilities included; maintaining multi-million dollar budget, project timing, equipment
capability, equipment and governmental specifications, software install and debug, mechanical assembly and
debug, equipment installation at customer site and service work.
Background and Professional Honors
Associate (Engineering Consultant) (2007 - Present)
Munro & Associates, Inc.
Advanced Manufacturing Engineer (2006 -2007)
Ford Motor Company
Manufacturing Engineer (2005-2006)
Visteon – Rawsonville Plant
Advanced Manufacturing Engineer for Product Design (2003 - 2005)
Visteon
Advanced Manufacturing Engineer (1998 – 2003)
Visteon – Ypsilanti Plant
Advanced Manufacturing Engineer – Special Projects (1995 – 1998)
Ford Motor Company
Manufacturing Engineer (1992 – 1995)
Ford Motor Company
Automation Design & Build Specialist (1986 – 1992)
Evana Tool & Engineering
Associates, General Sciences, Washtenaw Community College
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Lean Design® is a registered trademark of Munro & Associates, Inc. 13
CHRIS FERLAND
Specialized Professional Competence Expertise resides in project management, process design, lean manufacturing, and process and equipment
improvement.
As a prototype manager, led groups in the development and build of deliverables for test, engineering sign-offs
and start of production. Implemented cost saving methods and part tracking formats to decrease material waste.
Created work order and acceptance forms, product “Birth Certificates” and benchmarking forms that were added
to the company ISO documents. Aided Industrial Engineering groups in developing FMEA’s, build processes,
line layouts and manpower utilization. Assisted in production builds and training during pilot through SOP.
Prepared budgets, project timelines, and manpower capacity and forecasting records.
As a Project Manager / Sr. Manufacturing Process Engineer, managed personnel in the assembly of prototype
vehicles, wrote technical process specifications, assisted in product logistics, tracking and vehicle build kits &
shortages. Created quote packages including RFQ’s, SOR’s and process proposals. Established cost saving
measures utilizing common components and processes. Oversaw equipment installation, training of personnel in
build processes and developed process documentation. Responsibilities included managing a staff of 45 union
personnel responsible for vehicle builds, equipment cost, overall project timing, and operating cost. Maintained
open issue reports and vehicle project books including engineering sign-off documentation.
As a Manufacturing Process Engineer led several groups in the development of vehicle build process and
designs including weld drawings, plant layout proposals and investigations for multiple OEM products.
Streamlined design guidelines for layout and detail drawings. Acted as liaison between engineering and
assembly plants during tool installation, pilot builds and SOP. Member of the PDT (Product Development
Team).
Background and Professional Honors
Associate (Engineering Consultant) (2010 - Present)
Munro & Associates, Inc.
Prototype Manager (2007 -2010)
Recaro North America
Project Manager / Sr. Manufacturing Process Engineer (1997-2006)
MSX International
Sr. Manufacturing Process Engineer / Project Leader (1993 - 1997)
Modern Engineering
Supervisor - Prototype Manufacturing (1992 – 1993)
Ford Motor Company – New Model Program Development Center
Manufacturing Process Engineer (1991 – 1992)
J. S. McNamara Co.
Manufacturing Process Engineer (1987 – 1991)
Modern Engineering
Associates, Business Management, Macomb Community College
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Lean Design® is a registered trademark of Munro & Associates, Inc. 14
MARTY KOWALSKY Specialized Professional competence
At Munro, expertise resides with directing company efforts to provide a fully automated product
costing system for any manufactured product. Reduce to math modeling, approximately one hundred
fifty (150) of the most common manufacturing processes, and apply to a product definition to obtain an
accurate, reliable, and quick cost estimate. In this capacity, provide cost estimates for established
client costing projects. Provide information for engineering translation from one material and process
definition to another, establishing cost comparisons at equal product function and structure.
As an independent consultant with many years of practice, offered and provided product,
manufacturing, tooling, equipment, facility, risk timing, and benefits assessments in support of new
product ventures. Designed and developed alternate structural and manufacturing concepts to support
client needs and strategies. In a period of 20 years, I created more than 300 design translations from
metals to organic material approaches.
As an independent consultant, provided a regular marketing service of “selling to the military” with most of the
major worldwide plastics and chemical producers as direct clients. In a period of 30 years, I provided more than
1000 visits to US military installations, and the supporting contractor community. Succeeded in obtaining
$millions of research, project and product funding for the clients.
As an Engineering Manager, I administered, and led a group of engineers and designers on a variety of projects,
including a complete electric automobile. In this capacity, I allowed my company to offer design, development,
fabrication, tooling and test engineering.
Background and Professional Honors Costing Consultant- Developer (2001 – Present)
Munro & Associates
Independent Consultant – (1983 – 2009)
MSK Associates
Engineering Manager (1979 -1983)
Autodynamics Corporation of America
Engineering Supervisor (1972 – 1978)
Ford Motor Company
Design and Analytic Engineer (1969 – 1972)
Pratt & Whitney Aircraft (Untied Technologies)
BME- Mechanical – The City University of NY (1969)
BS –Architecture –The City University of New York (1965)
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DAVID WARNER
Specialized Professional Competence
Extensive experience in product development consulting, costing, electrical engineering and design for
manufacturing, David Warner offers clients special expertise in cost model development, electrical system cost
reduction coupled with facilitation, implementation, and training of Design Profit methods for improvements in
product development, quality and value. David has a proven track record helping clients enhance their products
and achieve dramatic improvements in product design, cost, quality and profitability through the application of
concurrent engineering and Design Profit principles.
David Warner has consulted for the last 4 years with companies in numerous industries, including consumer
electronics, agricultural, automotive, medical devices, food storage, defense and many others. Prior experience
includes advanced hybrid training development, service engineering for an OEM automotive manufacturer and
several years in the retail automotive service environment in both management and technical roles. David holds
an Associate of Applied Science degree in Electrical Engineering and certification as a Master Automotive
Technician.
Background and Professional Honors
Associate Consultant 2006 - Present
Munro & Associates, Inc. (Troy, MI)
Advanced Technology Vehicle Training Development 2004 - 2006
Raytheon Professional Services (Troy, MI.)
Service Engineer 2001 - 2004
TAC/Ford Motor Company (Allen Park, MI)
Service Technician 1979 - 2001
Various OEM Franchises
A.A.S. (Electrical Engineering), Cleveland Institute of Electronics, 1996
Certification (Automotive Service Technician), MOTECH, 1978
Alpha Beta Kappa National Honor Society 1996
ASE Automotive Service Excellence Master 1979 - Present
ASE Advance Engine Service Specialist 1980 - Present
State of Michigan Master Automobile Technician 1980 - Present
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CORY STEUBEN
Specialized Professional Competence Successfully completed nine cooperative assignments with Munro & Associates in a five year period. Project
and work responsibilities included: design analysis, detailed cost analysis, lean design, and data acquisition.
Several recent projects identified and established supporting data for EPA studies verifying fuel economy
feasibility. Benchmarked and established detailed manufacturing and assembly processes of the Toyota five and
six speed transmissions and the Audi DCT transmission. Completed a detailed thesis investigating the cost
differences of several valve train applications among the leading V6 engines. Performed a total accounted cost
study for three proposed electric park brake systems; investigating manufacturing and assembly processes at the
supplier and OEM level. Was an integral part of the benchmarking of engines from Audi, BMW, Nissan,
Chrysler, Ford, and General Motors. Supported data acquisition and lean design analysis on refrigeration
systems. Performed detailed costing and manufacturing analysis on large steering gear systems for several
manufacturers. Performed a benchmarking study for large agricultural equipment.
Thirteen years of hands-on technical experience in large diesel truck repair, auto repair, and 2-cycle motorcycle
engine maintenance. Experienced in engine, transmission, and hybrid assembly, manufacturing, and quality
analysis. Assisted on a variety of projects in the medical, aerospace, heavy equipment, defense, and automotive
industries. Versed in several CAD programs and produced computer generated drawings for conceptual redesign
aid. Facilitated brainstorming and design review meetings. Gained a wide range of knowledge from many
different industries in five years at Munro & Associates.
Background and Professional Honors Associate, Mechanical Engineer, (2010-present)
Munro & Associates, Troy Michigan
Junior Associate, (2005-2009)
Munro & Associates, Troy Michigan
BSME, Mechanical Engineering, Kettering University, 2010
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CHRISTOPHER FOX
Specialized Professional Competence Eight years of experience in robotic rapid prototype development and fabrication. Chris spent the past few months
studying and servicing class eight diesel on highway engines produced by the Detroit Diesel Corporation. He is
familiar with the EPA 2004 - 2010 regulations including exhaust gas recirculation (EGR) systems, diesel oxidizing
catalysts (DOC) diesel particulate filters (DPF), and selective catalytic reduction (SCR) systems.
Prior to working at the Detroit Diesel Corporation, Chris spent two semesters as a co-op in TRW's hydraulic slip
control systems test lab validating the slip control boost (SCB) ABS valves which were installed in all current
production GM hybrid trucks and SUV's at the time. In the summer of 2006, Chris helped to reduce the production of
aluminum scrap from radiators and heater cores at Automotive Components Holdings LLC's Sheldon Road plant. His
solutions resulted in a 40% reduction of aluminum scrap.
While in college, Chris worked on multiple robotics projects, including, but not limited to the Defense Advanced
Research Project Agency (DARPA) Intelligent Ground Vehicle Competition (IGVC) as well as the American Society
of Mechanical Engineers Student Design Competition. IGVC required students to design and build an autonomous
robot from the ground up, capable of carrying a 20 lb payload that could navigate an obstacle course as well as follow
GPS way points. Chris' team took 3rd place overall in the world in 2007. The 2008 ASME Student Design
Competition required students to design and build an autonomous robot which could clean a house hold double hung
sash window without touching the ground or surrounding walls. The robot had to be powered by a maximum of 24V
DC and the whole device could not exceed 1 kg in total mass. Utilizing CATIA's FEA capabilities and extensive
material research, Chris' team managed to produce a device in 6 weeks
Background and Professional Honors Application Engineer (2010 - Present)
Munro & Associates, Inc
Class Eight On Highway Diesel Engine Technical Support Engineer (2010)
Detroit Diesel Corporation
Hydraulic Slip Control Systems Test Engineer Co-op (2007)
TRW Automotive
Aluminum Operations Scrap Study Co-op (2006)
Automotive Components Holdings LLC
High School Robotics Team Mentor and Instructor (2004-2010)
University of Detroit Mercy
Machinist (2004-2010)
University of Detroit Mercy
BSME, Bachelors, Mechanical Engineering, University of Detroit Mercy, 2009
Graduated with honors
ASME, Student Design Competition 4th Place World Wide Winner, 2009
ASME, Student Design Competition 1st Place Regional Winner, 2008
DARPA Intelligent Ground Vehicle Competition 3rd Place World Wide Winner, 2007
Member - American Society of Mechanical Engineers
Member - Society of Manufacturing Engineers
Member - American Knife and Tool Institute
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JAMES HADLEY
Specialized Professional Competence Engineering experience developed through positions in research, development, and design. Research project and
position responsibilities: Technical advisor and manager for the team of graduate researchers. Responsible for
organization and communication between University and Ford researchers. Developed various aluminum foam
– polymer composite materials. Designed, tested, and analyzed manufacturing processes to create aluminum
foam – polymer composite materials. Designed predictive material theoretical models using finite element
analysis and neural networks. Published and presented aluminum foam – polymer composite research at ASME
and SAMPE engineering conferences. Design project and position responsibilities: Lead engineer on next
generation retractor design benchmarking analysis. Lead engineer in human factors study on effects of driver
movement on the seat belt system. Designed and operated testing systems for human factors study. Tested and
analyzed the design of several seat belt systems. Development project and position responsibilities: Designed,
manufactured, programmed, and operated durability testing robots. Tested and analyzed several product designs,
using environmental conditioning, including: power lift gates, power siding doors, power windows, door
modules, latching mechanisms, and seat belts. Completed compressive and tensile testing and analysis of
product design materials.
Background and Professional Honors Engineering Associate (2010-Present)
Munro & Associates, Inc. (Troy, MI)
Research Engineer and Liaison to Ford Adv. Research Lab (2008-2009)
University of Detroit Mercy (Detroit, MI)
Design & Benchmarking Engineer (2007)
Delphi, Seat Belts Adv. Design Group (Troy, MI)
Test Engineer (2006)
Delphi, Integrated Closure Sys. Test Lab (Troy, MI)
Masters, Mechanical Engineering, Mechatronics, University of Detroit Mercy, 2009
Bachelors, Mechanical Engineering, University of Detroit Mercy, 2009
Associates, Science, Oakland Community College, 2006
Certificate, CAD Drafting, 2005
Successful completion of the Fundamentals of Engineering Exam, June 2008
Recent Publications Dukhan, N., Rayess, N., and Hadley, J. “Characterization of Aluminum Foam-PP Interpenetrating Phase
Composites: Flexural Testing Results,” Mechanics of Materials 42.2 (2010).
Dukhan, N., Wang, F., Rayess, N., and Hadley, J., 2009, "Thickness Effect on Flexural Modulus of Aluminum
Foam PP Interpenetrating Phase Composite," Presented at MetFoam 2009.
Hadley, J.R., Rayess, N.E., Dukhan, N.I., and Houston, D.Q., 2009, “Mechanical Properties of Aluminum
Foam-Polymer Multifunctional Hybrid Materials,” Proc. IMECE2009, A.S.M.E., Nov. 13-19, 2009.
Hadley, J.R., Rayess, N.E., Dukhan, N.I., and Houston D.Q., 2009, “Tensile Strength of Aluminum Foam-
Polymer Interpenetrating Phase Composites,” Proc. 41st ISTC, S.A.M.P.E., Oct. 19–22, 2009.
Dukhan, N.I., Rayess, N.E. and Hadley, J.R., 2008, “Preliminary Structural Testing Results of Aluminum Foam-
Polypropylene Interpenetrating Phase Composites,” Proc. 40th ISTC, S.A.M.P.E., Sept. 8–11, 2008.
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MARK FAZI
Specialized Professional Competence Successfully completed two cooperative rotations with Toyota Motor Company. The first was in the
Engineering Design Services Group where he participated in Appearance Digital Assembly activities. This
activity included the virtual 3-D assembly of the Instrument Panel and Console of a current Toyota vehicle,
validating the current assembly prior to production. The organization of weekly Yokoten Meeting was another
top priority during this rotation. Here he was in charge of running meetings and setting up speakers to share in
the knowledge they have gained in the designing process.
During the second rotation at Toyota Motor Company he participated in product design with the Instrument
Panel and Console Group. Here he created 3-D parts and engineering drawings for the respective components of
the group. With these created drawings he was able to produce mock-ups that were used to validate their parts.
Another major responsibility during this rotation was the organization of open issues list. This included the
constant communication between Engineering, Styling and Plant personal to ensure proper closure of these
issues.
Successfully completed one cooperative rotation with DTE Energy. Responsibilities during this rotation
included: performing coal fineness testing and writing a test procedure to be used by current and future group
members for this process. The inspection of power generation components during outage. Designing a water
drainage system for the plant facility, to ensure proper water runoff. The creation of an internal group website.
These projects all were taken place in a power generation environment where they stress the importance of
safety.
Background and Professional Honors Engineering Associate (2010-Present)
Munro & Associates, Inc. (Troy, MI)
Instrument Panel and Console Engineer (2008)
Toyota Engineering Manufacturing North America, Saline Michigan
Engineering Design Services Engineer (2008)
Toyota Engineering Manufacturing North America, Ann Arbor Michigan
Performance and Testing Engineer (2007)
DTE Energy – River Rouge Power Plant, River Rouge Michigan
Masters, Mechanical Engineering, University of Detroit Mercy, 2010
Bachelors, Mechanical Engineering, University of Detroit Mercy, 2009
Successful completion of the Fundamentals of Engineering Exam, June 2009
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STEPHEN JU
Specialized Professional Competence Seven years of experience in a variety of industries including automotive, automation, alternative energy, and
design. Successfully completed Bachelor of Science in Mechanical Engineering and Master of Mechanical
Engineering, while working fulltime. Experience in Automation includes but not limited to designing and
detailing of special machines components, including vibratory bowl feeders that are tooled to orient parts of
various sizes and geometries, and fully integrated to customers’ product facilities. Experience in the automotive
industry includes but not limited to research, project planning, production line process composition, tool design,
offline gauge design, production line layout design, product throughput analysis, Overall Equipment
Effectiveness (OEE), database management, Zeiss CMM practical experience and reporting, Gauge R&R,
Correlation Study, Bias Analysis, work instructions, quality alerts, product containment protocols, PPAP,
PFMEA. Worked under the ISO9001 and QS9000; TS16949 standards. Successfully designed, manufactured,
and implemented a robot end effector for transferring engine blocks from conveyor to washing machine fixture.
Successfully designed and analyzed 3D tooling fixtures for a crankshaft induction heat treatment machine (the
CrankPro), as well as 2D machine layouts showing quench unit, power cabinets, de-ionized water systems, and
induction heater for Ford Motor Company (customer). Experience with metallurgical processes such as
grinding, polishing, and measuring Rockwell / Vickers hardness of metallic specimens. Experience in the
alternative energy industry includes design and detailing components and mechanisms for the Very High
Frequency (VHF) Amorphous Silicon machine that mass produces photovoltaic laminates. Experience with
creative and innovative product / lean design and analysis at Munro; designed new ferrule mechanism (patent
pending), and worked retrofitting existing trash compactor for commercial use.
Background and Professional Honors Engineering Intern
Linamar Corporation (1999)
3D CAD specialist / Engineering Intern
Automation Devices (2004)
Mechanical Design Engineer
Goertz + Schiele Corp. (2006-2008)
Mechanical Design Engineer
Inductoheat (2009)
Mechanical Design Engineer (2010)
United Solar Ovonic
Product Engineer
Munro & Associates (Present)
Masters, Mechanical Engineering, Oakland University, 2009
Bachelors, Applied Science in Mechanical Engineering, University of Toronto, 2008
Member of the Eastern Michigan SolidWorks User Group (EMSUG) for SolidWorks power users
Certificate in successfully completing training in Pro-E Wildfire and CATIA
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GREG JONES
Specialized Professional Competence
Lean Design Expertise- Munro & Associates, Inc.
• Senior leadership in project management and focused Lean Design studies
• Translation of extensive composite and automotive experience into part and labor savings
• Project management for design development in “Clean Sheet” golf cart program
• Four years on-site at Chrysler leading release engineers in PPIW- Product & Process Integration
Walls- Design development core team for manufacturing voice to engineering
• Led interior systems studies for Boeing 787 composite body aircraft
• Additional experience in Heavy Construction Equipment / Armored Military Vehicles
Composites / Engineering Resins Molding Process Expertise
• Over 200 studies / projects on automotive systems
• Budget responsibility $1.2M- 3 designers / all outside model development
• Expand marketing responsibility at OEM / Tier-1 advanced design groups
• Develop new Advanced Design Center / Virtual Reality Sport Utility Vehicle
• Define proactive concept programs / direct confidential OEM projects
• Corporate leadership- design concepts / Molding design review / Customer project management
Advanced Design Development and Program Management
Early career in consulting advanced design offices with experience in multiple industries / Experience developed
in manufacturing knowledge and plastics molding processes.
• Consumer housewares (Proctor-Silex mixers / coffee makers)
• Home power tools (Sears Craftsman portable hand drill / routers)
• Home floor care products (Sears Kenmore vacuum cleaners / wet & dry vac)
• Vending Equipment (Coca-cola soft drinks / commercial fountain dispensing)
• Computer housings (Color graphics workstations for industrial / military)
• Telecommunications (Northern Telecom telephone systems)
• Recreational equipment (Scuba equipment carrier / accessories)
Background and Professional Honors Munro & Associates- Lean Design Consulting- Design Prophet- 1998- Present
General Electric Corp- GE Plastics Automotive- Adv Design & DFMA Mgr- 1988-1998
Borg Warner Chemicals- Design+Eng Center- Design Manager- 1987 - 1988
McCalla-Lackey Associates-Consulting Design- Senior Project Manager- 1984 - 1987
Chromatics, Inc-Computer Manufacture- Design Engineer- 1983 - 1984
Jack Seay Design- Consulting Design- 1981 - 1983
Lee Payne Associates-Consulting Design- 1980 - 1981
Industrial Design Associates-Consulting Design 1978 - 1980
Bachelor of Science 1978- Industrial Design
Georgia Institute of Technology
(+2 years of business management study)
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DANIEL MCCARTHY
Specialized Professional Competence Expertise resides in product engineering, product cost reduction, quality enhancement and lead time reduction
through the strategic adoption and implementation of concurrent engineering practices. Over twenty five years
of experience in competitive benchmarking, design for assembly, program management, cost reduction and
Quality improvement.
Dan has facilitated Lean Design® workshops for a variety of companies, including ATK, American Science &
Engineering, BAES, Boeing, BF Goodrich Aerospace, Chrysler Corporation, Case Corporation, DRS, General
Dynamics, General Electric, General Motors, Ingersoll-Rand, Medtronic, Motorola, Raytheon, Rolls-Royce,
Texas Instruments, etc. A principal developer of the Munro Lean Design and Quality Report Card
methodologies, Daniel has also developed customized Product Development tools for his clients, including an
early part costing tool and a Design for Sustainability module for Boeing Aircraft Company.
Contributing author to the SME Tool and Manufacturing Engineers Handbook (1992 Edition) in the areas of
Design for Serviceability and Design for Disassembly.
Background and Professional Honors Design Profit (1989 - Present)
Munro & Associates, Inc.
Robotics Specialist – Corporate Design for Manufacture Consultant (1984 - 1989)
North American Philips Corp.
Systems Engineer (1979 - 1984)
General Dynamics – Electric Boat Division
Tooling Engineer (1978- 1979)
United Technologies – Pratt & Whitney Aircraft
MS, Manufacturing Management Rensselaer Polytechnic Institute, 1983
BSME, Bachelors, Mechanical Engineering Technology, University of Massachusetts, Dartmouth 1978
Member- Society of Manufacturing Engineers
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WILL SULLIVAN
Specialized Professional Competence Will is an engineering, cost, quality and operations management professional with extensive global and
domestic experience in product development and manufacturing. He has a track record of designing cost
efficient products and processes which increase sales through on time delivery of quality products within
budget. He demonstrates the ability to develop and maintain excellent customer relationships that create new
business opportunities. He is an accomplished leader that develops new employees through mentoring. His
experience spans the development of products from concept through all stages of a program and successful
launch. Will started his passion for mechanical invention and manufacturing at a young age and focused his
learning on manufacturing engineering best methods from the start. Attending industrial arts classes and trade
school to become a certified Tool and Die maker he then went on to design and estimate stamping processes for
Ford Motor Company. Once he had mastered stamping processes he moved on to the development of plastic
products and then many other manufacturing processes and materials. He left Ford Motor Company to pursue a
leadership role at United Plastics and launched many new manufacturing projects for various industries
eventually rising to become the engineering manager. He then became the chief engineer at Allmand and
Associates a very dynamic organization where an engineering concept could be quickly shaped and turned into a
real product. Will also became the Director of Quality at Allmand leading the way to ISO-9000 and Q1
certifications at the company. Then upon rejoining Ford he moved quickly into the financial decision making
world guiding many programs around the globe through concept, development, approval, build and launch
phases. Upon retiring from Ford he joined Magna Steyr in Supply Chain Management designing and launching
programs. Will joined Munro and Associates one year ago focusing on the development of cost estimating
modules and implementation of cost savings opportunities.
Background and Professional Honors Senior Cost Engineer (2009-2010)
Munro & Associates, Inc.
Sr. Cost & Quality Engineering Leader (2007-2009)
Magna Steyr, Troy Mi.
Finance Supervisor (1993-2007)
Ford Motor Company, Dearborn, Mi.
Chief Engineer & Director of Quality (1990-1993)
Allmand and Associates, Livonia, Mi. Engineering Director (1984-1990)
United Plastics / Gilreath Manufacturing, Southfield MI Product Cost Estimator (1969-1984)
Ford Motor Company, Dearborn, Mi.
MBA, Leadership Studies, Baker College, Auburn Hills, MI 3.95 Suma 1999
BBA, Management, Davenport University, Dearborn, MI 3.86 Magna 1995
ASA, Project Engineering, Henry Ford Community College, Dearborn, Mi. 1977
Tool and Die Making Degree, Henry Ford Community College, Dearborn Mi. 1971
ASA, Liberal Arts, Oakland Community College, Auburn Hills, Mi. 1969
Certified Project Management Professional 2000
Federal Certification Journeyman Tool and Die Maker 1972
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SANDY MUNRO
Specialized Professional Competence Sandy Munro is a frequent speaker and advisor to some of the world's top executives on implementing
change and innovative development strategies. Called a visionary and master innovator by NASA,
Sandy Munro offers his clients a wealth of perspective and a penchant for technology transfer.
Although he began his career in the automotive and aircraft industry he has worked extensively with
global corporations of all types along with their suppliers. Sandy’s experience and insight cuts across
virtually every segment of the manufacturing industry, from Barbie to the Space Station, which gives
him a unique advantage in the area of technology transfer.
One of the pioneers in the application of design for assembly (DFA) Sandy founded his consulting
firm, Munro & Associates, Inc., in 1988 and developed an enhanced process calling it design for
manufacturability or DFM®. These principles were developed to help North American manufacturers
harness the power of concurrent engineering to reach new levels of global competitiveness.
Sandy began his career as a toolmaker in Windsor Ontario, he worked his way up the ranks to designer
and eventually became Engineering Manager at Valiant Machine Tool Company, a world recognized
specialty Tool Company.
In 1978, Sandy joined Ford Motor Company and shifted roles from machine tool and automation
designer to manufacturing engineer. After several projects where he helped increase productivity on
engine assembly lines, he was promoted to Senior Automation Specialist, where he supervised
installations like the Essex Engine Plant and the development of new, more productive engine
manufacturing lines like the Lima Ohio Plant.
In 1982 Sandy met Dr E. Deming and everything in his carreer changed. Dr. Deming’s phrase of “As
variation is reduced Quality will increase” resonated with Sandy and he became a zealot in reducing
variation but in a different way; as Sandy says “all variation stems from design.”
The Deming spirit and philosophy is evident in all the Munro products and services.
After successfully implementing design for assembly principles at Ford, Sandy was named Corporate
Coordinator - Design for Assembly for the automaker. In this new position, Sandy helped Ford utilize
DFA to save billions of dollars, improve quality and reduce development cycles during the early
1980's. For his efforts Sandy was nominated for the Henry Ford Award twice.
In 1988 Sandy was convinced by Dr Deming to leave Ford and start his own company which became
Munro & Associates, Inc.
Since that time, Munro & Associates, Inc. has helped manufacturers of all types of products -- from
airplanes to toys, appliances to medical devices, and automobiles to electronics -- to save an estimated
$50 billion and retain or return to North America hundreds of thousands of jobs. Also, his company’s
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service portfolio has expanded to include; competitive benchmarking, at their 30,000 sq.ft. facility,
strategic product planning, and Design Profit® a number of interrelated software tools to help
manufacturing companies succeed. Design Profit includes Lean Design® a much enhance version of
their DFM® process, Munro Quality Report Card®, which can help companies reach six sigma quality
levels, The Wall Process® a tool to stop program creep and TechTransfer a search engine to assist in
redesign effort.
With more than 30 years of experience designing, building, and processing components, Sandy brings
clients a remarkable breadth of experience. He has chaired and spoken at numerous engineering
conferences and symposia across the globe and has lectured at Stanford, Purdue, the University of
Michigan, and many other universities.
Background and Professional Honors President and CEO, (1988- Present)
Munro & Associates, Inc.
Ford Motor Company (1978 – 1988)
DFM Corporate Coordinator
Valiant Machine Tool (1974 - 1978)
Chief Engineer
Machine Tool Shops throughout Windsor and Detroit (1966 - 1974)
Chief Engineer to Tool Maker
St. Clair College: Mechanical Technologist classes
University of Windsor: Business courses
Detroit Mercy: Management courses
Stanford University – taught DFA/DFM and innovation design courses
Member, Society of Automotive Engineers
Member, Society of Manufacturing Engineers
Member, Engineering Society of Detroit
He is also the Chairman of NASA MI SATS (Small Aircraft Transportation System) and a board
member of NASA NCAM. (National Consortium for Air Mobility)