Yousuf Rehman

• Led manufacturing engineering for MY30 Expedition/Navigator/F-150 new model design phase at KTP
(Kentucky Truck Plant), driving VME feasibility from TMR to PSC in GPDS, including cycle line layouts and
plant configurations.
• Wrote tooling design/build/installation scopes and collaborated with PD, STA, MP&L, NMP, MTDC teams on
Program Cost Studies and management presentations through Ok to Buy.
• Identified potential manufacturing issues in body-on-frame SUV/truck designs, supporting Major
Architecture/High Hurts resolutions to mitigate launch risks pre-production.
• Documented preliminary Lessons Learned to update Expedition/Navigator/F-150 manufacturing standards
during design.
• Prepared process sheets post-Final Design Judgemental & Supported plant tooling structure.

• Led manufacturing engineering activities for MY30 Expedition/Navigator/F-150 programs at KTP (Kentucky
Truck Plant), driving VME feasibility, cycle line layouts, and plant configuration through GPDS milestones.
• Developed tooling design, build, and installation scopes, collaborating with cross-functional teams on Program
Cost Studies and management reviews through Ok to Buy.
• Supported ICE, FHEV, and EREV manufacturing programs within high-volume automotive environments.
• Identified and resolved manufacturing risks in high-volume SUV/truck assembly, impacting quality, cost, labor,
and launch readiness.
• Supported Major Architecture/High Hurts issue resolution to mitigate pre-production launch concerns.
• Led and supported DCV (Design Confirmation Vehicle), TT (Tool Tryout), PP (Pilot Production), MP1/MP2
(Mass Production Phase 1/Phase 2) manufacturing build activities across Canada, Mexico, China, and the United
States assembly plants.
• Documented Lessons Learned and updated Expedition/Navigator/F-150 manufacturing standards to support
continuous improvement initiatives.
• Supported tooling installation, body-on-frame processes, plant start-up, buy-off, FAT/SAT activities and shared
line production launches.
Key Projects:
• Developed process sheets (post-Final Design Judgement), plant layouts, tooling scopes, and manufacturing
documentation using GPDS methodologies.
• Collaborated cross-functionally with PD (Product Development), STA (Supplier Technical Assistance), MP&L
(Material Planning & Logistics), NMP (New Model Programs), MTDC (Manufacturing Technical Development
Center), Quality, Controls, and Manufacturing teams.
• Drove process improvement initiatives enhancing safety, quality and productivity in automotive manufacturing.

• Lead and manage multiple projects across Ford’s F59 and F53 subassemblies, ensuring on-time, on-budget
delivery while optimizing quality and safety standards.
• Oversee all aspects of project delivery, from planning and scheduling to execution and completion, for Detroit
Chassis Plant in Michigan.
• Direct a cross-functional team of engineers, process specialists, and quality teams to implement new process
controls and ensure the seamless production of vehicle components.
• Spearheaded the integration of new torque systems, reducing rework by 20% and improving product quality.
• Supervise the end-of-line equipment by building new strategies.
• Monitor the first time through rate for entire EPP system including brake fill and fluid fill at final line.
• Conducted detailed project risk analysis and managed claims and disputes, resulting in a 30% reduction in
overall claim costs.
• Utilized earned value management (EVM) techniques to track project performance and make timely
adjustments, ensuring successful project completion.

• Led and managed multiple manufacturing projects for Ford F59 and F53 subassemblies, ensuring on-time, on
budget delivery, while optimizing quality and safety standards.
• Managed full project lifecycle activities including planning, scheduling, execution, commissioning, and launch
support at Detroit Chassis Plant in Michigan.
• Directed a cross-functional team of engineers, process specialists, and quality teams to implement new process
controls and ensure the seamless production of vehicle components.
• Spearheaded torque system integration projects, reducing rework by 20% and improving product quality.
• Integrated Rockwell FactoryTalk MES to support production execution, traceability, and quality workflows.
• Established a Gemba walk methodology to drive plant-floor problem solving and improvement initiatives.
• Monitored FTQ, KPIs, OEE, downtime, brake fill, and fluid fill performance metrics across production systems.
• Conducted detailed project risk analysis, claims management, and dispute resolution, reducing overall claim
costs by 30%.
• Performed joint and fastener studies evaluating clamp load, friction, assembly access, and serviceability.
• Applied torque-angle and torque-to-yield strategies for critical fasteners, including chassis, brake, suspension,
BIW, and powertrain systems.
• Implemented torque monitoring, MES integration, fastener validation, traceability, and Poka-Yoke error
proofing systems for safety-critical assemblies.
• Utilized Earned Value Management (EVM) techniques to track project cost, schedule, and performance.
Key Projects:
• Led the C2 chassis line setup including wireless tools, sensors, torque systems, and complete error-proofing
implementation, managing full project lifecycle and significantly improving the lines efficiency.
• Managed a $2M AIS system implementation project, supporting timely production quality.
• Integrated MES with tooling, torque systems, and automated error-proofing controls.
• Managed ECR/ECO and CM/PCN activities, supporting engineering and process changes.
• Supported FAT, SAT, and UAT activities for tooling, equipment, and manufacturing systems.
• Managed $1M rear axle implementation project for F59/F53 subassembly lines, including tooling, sensors, and
error-proofing systems.

• Led torque engineering projects at GM, providing expertise in fastening systems and torque processes for
automotive manufacturing.
• Directed the implementation of new torque systems that led to a 15% reduction in defects and rework.
• Managed the training and development of engineers and operators across GM plants to ensure consistent use
of torque control systems.
• Collaborated with cross-functional teams to implement innovative solutions, including the introduction of new
torque monitoring systems.
Key Projects:
• Assembly Line Setup for Trim, Chassis, and Framing: Led the setup and coordination of assembly lines for
trim, chassis, and framing. Ordered and organized all tools, with a total cost of over $1M.
• KUKA Supplier Coordination: Managed the installation and setup of the assembly lines and tools in
collaboration with KUKA, with a total cost of $1.8M.
• Ubisense Sensor System Installation for Wireless Tooling: Led the installation of the Ubisense sensor system
for wireless tooling at the CAMI assembly plant, which is a replica of Factory Zero in Hamtramck. Ordered all
required components and systems to facilitate the transition to electric vehicle manufacturing.

Manufacturing)
• Led torque engineering projects and fastening system improvements for automotive manufacturing operations
at General Motors.
• Led root cause analysis using 8D/G8D and 5-Why methodologies, to drive permanent corrective actions.
• Implemented new torque systems, reducing defects and rework by 15%.
• Trained engineers and operators on torque control systems and manufacturing process standards.
• Collaborated with cross-functional teams to implement torque monitoring and process improvement solutions.
Key
• Led the setup of trim, chassis, and framing assembly lines valued at over $1M.
• Managed $1.8M assembly line tooling installation projects in partnership with KUKA.
• Supported Wave 5 and Wave 7 system integration activities for multi-plant manufacturing launches.
• Developed analytics dashboards using JMP, Minitab, and Tableau to support manufacturing and quality
performance analysis.
• Supported SPC, MSA, and DOE studies for process validation and quality improvement.
• Led the installation of Ubisense sensor system for wireless tooling at the CAMI assembly plant, to support EV
manufacturing transition activities.

• Provided technical sales and customer support across North America.
• Programmed Siemens VSD/VFD smart compressor systems to optimize performance and PSI requirements.
• Provided technical support and troubleshooting for compressor systems across the United States by optimizing
programming settings.
• Managed end-to-end parts sales operations, including customer coordination, technical support, and timely
order fulfillment.
Key Projects:
• Generated annual parts sales revenue of $300K-$400K across compressor products and services.
• Managed inventory control, order processing, and international shipment coordination.
• Oversaw customer service scheduling and field service dispatch activities.
• Improved sales tracking, reporting systems, customer satisfaction and lead-time performance through process
optimization initiatives.
• Conducted site visits for technical service and product presentations.
• Led and coordinated with parts sales and logistics teams, supporting domestic and international operations.
• Implemented CRM systems and generated KPI reports to support sales and operational performance.

• Managed production engineering for automotive subassemblies, improving production efficiency and
minimizing downtime.
• Led initiatives to streamline manufacturing processes and integrate automation technologies, achieving a
10% improvement in overall production efficiency.
• Collaborated with quality control teams to address defects and ensure compliance with Toyota’s high-
quality manufacturing standards.
• Managed and ensured smooth operation of the Trim Line, focusing on minimizing faults and ensuring
operators performed tasks correctly and efficiently.
• Maintained close contact with process engineers and controls engineers to guarantee that all systems and
processes ran seamlessly.
• Regularly ensured the proper functionality of robots on the production line and addressed any operational
issues proactively.
• Worked with Toyota North America’s quality and design engineers to ensure the assembly system was
working as expected and reported any system performance issues.
• Collaborated with Toyota’s head office and internal teams to facilitate the implementation of new
engineering changes to enhance product quality.
• Led efforts in sourcing new parts and collaborating with responsible teams for procurement when needed.
• Oversaw and ensured that all process changes and updates were properly communicated and executed,
ensuring minimal disruptions in production.

• Managed production engineering activities for automotive subassemblies, improving production efficiency and
minimizing downtime.
• Led automation and process improvement initiatives, increasing production efficiency by 10%.
• Collaborated with Quality control teams to resolve defects and maintain compliance with Toyota manufacturing
standards.
• Oversaw Trim Line operations to ensure production quality, process accuracy, and operator efficiency.
• Worked closely with Process and Controls Engineers to maintain stable manufacturing operations and systems
performance.
• Monitored robotic systems and resolved production line issues to minimize operational disruptions.
• Partnered with Toyotas head office and internal teams to support engineering change implementation and
product quality improvement.
• Contributed to sourcing efforts, procurement, and implementation of new production parts.
• Managed communication and execution of all process changes, with minimal production disruption.
Key Projects:
• Supported a $50M Toyota production facility expansion project.
• Developed production baselines and monitored manufacturing performance metrics.
• Led Lean Six Sigma and Kaizen continuous improvement initiatives, collaborating with Maintenance team and
external contractors.
• Played a key role in the manufacturing of Lexus 2023 Pilot Models.