Our Team

About  John Deradoorian

John brings over 8-years’ experience in the Tool & Die field. He has significant experience in machine shop processes and workflow optimization within die shops. In addition, he has worked extensively in implementing lean principles into die and tooling manufacturing to reduce man-hour costs. John has experience working with progressive dies, transfer dies, and specialty machines. He has also worked comprehensively in the manufacturing of perishable die tooling.

Education

• Associates in Applied Science, Oakland Community College
• Department of Labor Tool and Die Apprenticeship
• Bachelor’s degree, Industrial Technology & Management, Ferris State University

Experience

• 4-years in Die Shop Management
• 4-years as a Graduated Tool & Die Maker
• 8-years Machining

Skills

• CAD/CAM systems
• CNC Machining, Wire EDM, Surface Grinding, Hard Milling
• Die Manufacturing and Try-out
• Process Engineering

Becky joined the team in 2016 and serves as Controller at World Headquarters. As Controller, Becky provides fiscal management oversight and budgetary planning with additional responsibilities of internal controls and financial reports. Prior to joining The Phoenix Group, Becky spent more than 10 years providing financial leadership, budgetary planning and operational oversight to several corporations in the Dayton area. She earned her Associates of Applied Science and is pursuing a degree in Public Administration.

About Jaime Hernandez

Bio

Jaime has been supporting the Phoenix Group since 2015 in multiple roles that have included; Die and Formability Engineer, Technical Customer Service Engineer and Sr. Application Engineer. Jaime has supported multiple Stampers, Mills, and Processors of aluminum/steel in their stamping process. A few of his roles included providing problem solving, TCS Support, launch support, forming solutions using formability science, training, assessments, and formability system implementations. Jaime took the lead of Mexico Operations for Phoenix in June of 2017.

Before coming to The Phoenix Group, Jaime invested more than 10+ years working in Magna Cosma International, first in Die Maker position, and then as a Die & Formability Engineer in charge of a formability team to solve forming issues and metal saving implementations.

Education

• B.S Mechatronics Engineering- Kino University. Graduated with Honorable Mention.
• B.S Electronic and Automation-Technological University of Hermosillo

Experience

• 15+ Years of experience in the Stamping industry

Skills

• Great understanding of Stamping Process (inputs and outputs)
• Use of the formability science to solve forming issues, including die evaluations and the action plan elaboration
• Management and Leadership
• Technical Customer Services
• Root Cause Analysis
• Die Optimization and Problem Solving

Key Projects

• Ford CD3 Dies Maintenance
• Ford CD4 Launch Support and Maintaneance
• T1XX Project, Launch Support during 2018 & 2019
• MP16 project Jeep Compas, Launch Support

About Larry Przekora

Bio

Joining our team in 2015, Larry brought over forty years of manufacturing, manufacturing engineering, quality, production troubleshooting and cost reduction experience.  Before coming to work for The Phoenix Group he spent thirty eight years with General Motors on Manufacturing assignments including machining, press operations, assembly activities and testing of all finished products.  He was also instrumental in the startup of three new product lines and instituted Lean and Global Manufacturing Systems in several GM facilities.

Education

• BA – Management of Human Resource, Spring Arbor University

Experience

• 40 years Manufacturing (machining, assembly, stamping, heat treat and welding), Safety and Quality Management, Manufacturing Engineering, Industrial Engineering, Project Management, Material Handling and Logistics Management, Labor Relations

Skills

• Global Manufacturing System/Toyoda Production System Implementation
• Principles of Lean Manufacturing
• Statistical Process Control/6 sigma
• Red X Problem Solving
• Safety & Quality Management
• Team Concept Implementation
• Buffer and Constraint Management
• Level 2 containment; 2nd party audits
• Waste Reduction
• Workplace Organization
• Tooling Control

Certifications

• Global Manufacturing System
• Red X Problem Solving
• Lean Manufacturing
• Team Concept Implementation
• Six Sigma
• Statistical Process Control

Key Projects

• Formability Project Leader – Tier 1 Supplier, 2015 - 2016
• Ford Tool Die Council, 2016 – 2018
• AK Steel – Due Diligence Team, 2017
• Quality Containments – Tier 2 Supplier, 2017 - 2019
• Plant Assessments – Tier 2 Supplier, 2017 - 2019
• Data Collection and Problem Solving, Tier 2 Supplier, 2019

About Menachem Kimchi

Bio

Menachem Kimchi Joined TPG as a welding/joining engineering consultant in 2013, he is also an associate professor in the Welding Engineering program at The Ohio State University. Previously, for 27 years, M. Kimchi was a principal research engineer, technology leader, and business development manager for EWI, and has published over 100 technical papers in area of Resistance and Solid State Welding processes of advanced materials, and published the book “Resistance Spot Welding Fundamentals and Applications for the Automotive Industry”

Education

• B.S. Chemical Engineering, Israel Institute of Technology
• B.S. Welding Engineering, The Ohio State University
• M.S. Welding Engineering, The Ohio State University

Experience

• Technical specialist with more than 30 years of experience in welding and joining in the automotive and light manufacturing industries. Specializing in consulting, engineering problem solving, quality management and work force training.
• Initiated and managed development projects in areas of Resistance Spot Welding, Resistance Seam, and Projection Welding, specializing in resistance welding high-strength steels and aluminum alloys. Other major areas of technical expertise include weldability of steels with metallic and nonmetallic coatings and electrode materials.
• Responsibilities included establishing advance knowledge in areas such as High-Frequency/ERW welding and the recently developed magnetic pulse and deformation resistance welding technologies. Considered as an industry expert in tube and pipe production as it relates to the high-frequency welding process.
• As a technical specialist and business development manager, was responsible for the consumer and industrial product and automotive markets managing customer relationships with the major OEMs and Tier one suppliers.

Skills

• Specialist in automotive materials and welding processes
• Technical specialist in Resistance Welding processes
• Technical specialist in Solid State Welding processes
• Monitoring and control of welding processes
• Automotive welding specifications and testing
• Failure analysis of welded joints
• Manufacturing process development and modification
• Technical specialist in tube and pipe production
• Work force training - welding

Certifications

• Provided certification when performed teaching and industry training for AWS, SME, OSU and other organizations.

About Craig Jankowski

Bio

Craig brings to us over twenty five years’ experience in the Tool & Die trade, working at Tier 1 & 2 and Chrysler Tool and Die facilities.  At Chrysler, Craig spent thirteen years as a die maker working on large steel and aluminum body panels with several of those years operating the Argus optical measuring system. He also worked as Manufacturing Engineering Operations Support Analyst and Formability Engineer for stamped aluminum parts, circle grid and thinning analysis, and support for material blanking.

Education

• Associates Degree (General Studies) Baker College, Auburn Hills, MI
• Bachelor’s Degree, Industrial Management, Baker College, Auburn Hills, MI
• MBA, Baker College Center for Graduate Studies, Flint, MI

Experience

• 22+ years Die Maker
• 2 years, Manufacturing Engineering Operations support analyst
• 1 year, Formability Engineer
• 4 years, Director of Forming systems

Skills

• Die Build, Die Tryout, Draw dies
• Soft tooling binder development
• CGA, TSA, Formability systems installation, GMAW, GTAW

About Wilfred Fras

Bio

Since 2005 Wil has brought The Phoenix Group his expertise in stamping die/part quality improvement, throughput improvement, material utilization, strain analysis, die optimization, installation of formability and reference panel systems, new vehicle launch process analysis, and Tool and Die training programs. Wil spent eighteen years with General Motors Corporation in manufacturing development and prototype die tryout, strain analysis software development for automotive stamping dies and stretch form bead development and improvements.

Education

• Associate Degree, Baker College (Applied Technologies)
• Online continuing education process at GM in CDA/CAM, materials application and tooling development
• Classes through Stanford, GMI (Kettering University)
• Attended classes at Wayne State University, Oakland University, Oakland and Macomb Community Colleges.

Experience

• 45 Years as a Journeyman Tool & Diemaker, Die Tryout & Follow-up
• 20 years of providing instruction in die design and stamping process control improvements/stabilization

Skills

• Die Optimization and Problem resolution
• Strain Analysis (surface and thickness strain)
• Trained and Certified Formability analysts in 13 Automotive manufacturers
• Conducted engineering training classes in sheet metal basic, formability, design for Manufacturing in Stamping, and Trim, Flange, Pierce and Hem die basic designs.

Certifications

• General Motors Technical Education Program, Silver Certificate in Advanced Technology

Key Projects

• Trained formability lab analysts and Installation of formability lab for Automotive Bodyside Scrap reduction project at OEM resulting in >35% scrap reduced to < 4% in 6 months 1999 and permanent formability capability. 5 GM stamping facilities between 2000 and present.
• Training of formability lab analysts and Installation of formability lab at OEM Stamping facilities, 2002-2005, 3 CHY, CHY-Bentz, stamping facilities
• Training of formability lab analysts and Installation of formability lab at OEM Stamping facilities, 2006-2009, 7 FMC, stamping facilities
• Contribute to technical content of WAS AHSS User Guidelines 2011-2013
• Provide overview training of that material to WAS engineering community members. 2014-2015

About Fernando Valenzuela

Bio

Fernando started his career with The Phoenix Group on February 2019 providing dedicated Technical Services to MISA (Marubeni Itochu Steel America). He has been offering TCS support that includes Problem Solving, Management, Quality, Manufacturing Evaluations and Root Cause Analysis of Technical issues to MISA’s customers in Mexico.

Fernando’s previous experience includes a Die Maker position in charge of die protection and die maintenance.

Education

• B.S. Industrial Engineering in Productive Process-Technological University of Hermosillo

Experience

• 12+ Years in stamping industry in the areas of Logistics and Tool and Die.

Skills

• Perform machining operations to a high degree of tolerance.
• Tooling service and setup.
• Build, maintain, improve, repair and modify tools, dies and fixtures as instructed.
• Die protection sensors
• Welding TIG, MIG

Key Projects

• CD3 Ford/Magna SFT
• CD4 Ford/Magna SFT
• Support Renault/Magna Brazil
• Support Honda/Magna SLP
• CSL BMW and Mercedes Benz

About Russ Balzer

Bio

Since 2007 Russ has provided expertise in various roles at The Phoenix Group. Russ began his career with Phoenix as a Lab Supervisor, then took on responsibility for Safety and Quality Compliance. In addition to supporting our Quality System services projects, Russ currently serves as Technical Director for WorldAutoSteel, a global consortium of steel producers serving the automotive market. As Technical Director, Russ manages a variety of engineering projects, and has tactical and strategic responsibilities in WorldAutoSteel’s efforts to use and promote Life Cycle Assessment (LCA).

Education

• B.S.S. Environmental Compliance, Ohio University

Experience

• 15+ years Mfg. Operations Management
• Engineering Project Management
• Safety & Quality Management Systems

Skills

• Materials Testing
• Project management
• Life Cycle Assessment (LCA)
• Safety & Quality Management Systems
• SQA - Level 2 containment
• 2nd party audits

Certifications

• Lead Auditor ISO9001:2015
• Lead Auditor IATF16949:2016
• Life Cycle Assessment Certified Professional

Key Projects

• QMS Auditing:

Midwest Fabricating – internal audit
Hayes Performance Systems – internal audit
AK Steel (AW) – internal audit

• Project Management:

WorldAutoSteel – manage global Life Cycle Assessment (LCA) policy project, including advocacy, and education, across a wide range of stakeholders (government, academia, industry).
WorldAutoSteel – manage modeling and engineering projects including component design, benchmarking, LCA and cost modeling.

About George Coates

Bio

Since 1991, George has been providing engineering and consulting services for industry leaders in the steel, automotive, and manufacturing industries. George’s areas of expertise include: management and strategic consulting, project management, automotive stamping throughput improvement, supplier metal conversion, metal formability and reference panel systems, and new vehicle launch manufacturing support. George is an active contributor to WorldAutoSteel technical programs, including project manager / instructor for AHSS Application Guidelines, Version 6.0.

Education

• B.S. Metallurgical Engineering, University of Cincinnati
• MBA coursework, Miami University (Ohio)

Experience

• Twenty-eight years with The Phoenix Group
• 10 years with a major US steel producer
• 5 years with the Procter and Gamble Company
• 10+ years Consultant to WorldAutoSteel

Skills

• Management and strategic consulting
• Leadership development
• Team installations
• Project management
• Metal formability and reference panel systems
• New vehicle launch support
• Technical director for the WorldAutoSteel program staff; emphasis on AHSS implementation solutions, strategic implications for steel in future mobility, materials and environmental impacts from vehicle light weighting.

Case Studies

WorldAutoSteel

About Melissa Norman

Bio

Melissa oversees all Quality System services and strategy for The Phoenix Group. Melissa began her 25-year career in manufacturing, working as an Industrial Engineer, Lean Manufacturing Engineer and Logistics Manager at General Motors / Delphi Automotive. Later, Melissa transitioned her career to work as an independent Quality Management System consultant. Since 2006, Melissa has worked with The Phoenix Group in various roles, but her primary responsibilities have been to lead and manage the largest sector of our Technical Outsourcing business, as well as develop and direct our Quality System services projects. Melissa’s areas of expertise with Quality Management Systems include training, project management, system development and implementation, quality coordination, consulting and internal auditing. Melissa’s QMS consulting career includes the following:

• ISO 9001, ISO 13485, ISO 17025, ISO 14001
• AS 9100
• IATF 16949 (previously ISO/TS 16949)
• Quality Core Tools

Education

• Master of Science in Operations Management, Kettering University – Flint, Michigan
• Bachelor of Science in Human Factors Engineering, Wright State University – Dayton, Ohio

Experience

• 25 years manufacturing experience (industrial engineering, ergonomics, lean manufacturing, material handling and logistics, operations management, project management)
• 15 years Quality Management System experience (training, auditing, QMS design/implementation, project management)

Skills

• Quality & Environmental Management Systems (ISO 9001, IATF 16949, ISO 13485, AS9100, ISO 14001)
• Supplier Quality Assurance (Level 2 containment and 2nd party audits)
• Quality Core Tools (PFMEAs, Control Plans)
• Value Stream Mapping

Certifications

• Exemplar Global-Certified ISO 9001:2015 Lead Auditor. AIAG & Plexus International – Southfield, MI
• AIAG IATF 16949:2016 Supplier Auditor Certification AIAG & Plexus International – Southfield, MI
• AIAG & VDA Process FMEA: Transitioning for Practitioners AIAG & Plexus International – Southfield, MI
• Transition to ISO 9001:2015 Including Risk Management SRI – Indianapolis, IN

Key Projects

• ISO/IATF Gap Analysis, Tier 1 & 2 Suppliers, 2017-2019
• ISO/TS/IATF QMS system development/improvement and project management, Tier 1 & 2 Suppliers, 2006-2019
• ISO/TS/IATF internal audit – Tier 1 & 2 Suppliers, 2006-2019
• ISO/TS/IATF QMS Overview training – Tier 1 & 2 Suppliers, 2008-2019
• ISO/TS/IATF Internal Auditor training – Tier 1 & 2 Suppliers, 2008-2019
• Core Tools training – Tier 1 & 2 Suppliers, 2008-2019
• Core Tools development (PFMEA/Control Plan) – Tier 1 & 2 Suppliers, 2008-2019
• SQA Level I and II Containments and Supplier Audits – Tier 2 Suppliers, 2008-2012, 2015

About Kirk D. Wiley

Bio

Starting his career on the manufacturing line at General Motors, Kirk has experienced nearly every aspect of the automotive and manufacturing industries, developing a comprehensive perspective for clients. Kirk’s areas of expertise include: systems design and team processes, metal formability, stamping and assembly optimization, die shop management, throughput improvement, process engineering, manufacturing systems design and implementation, supplier metal conversion programs, manufacturing cost savings, production troubleshooting and die optimization, and tool and die training programs.

Education

• BBA Industrial Marketing, Western Michigan University
• Coursework completed, MS Manufacturing Management, Kettering University

Experience

• 25 years manufacturing experience
• Operating Systems design, implementation and maintenance

Skills

• Team concepts
• Leadership development
• Tool & Die training programs
• Formability
• Lean applications to maintenance departments

Key Projects

• Manufacturing Cost Savings project at Chrysler Sterling Stamping. Realized $3.4M savings on a 10 month, A Transfer press project , $1.5M savings on a 8 month, B Transfer press project.
• Formabiility System Installation at 12 OEM Stamping Plants. T&D training events at another 6. Significant savings recorded in individual case studies.
• Leadership Training design and delivery across the Ford Motor Company Stamping Business Unit plants.
• Pioneered application of Lean Manufacturing principles to Tool & Die department operation.

Case Studies

• 418th Civil Affairs Battalion