S. David Bolton

Professional Profile

Senior Manufacturing Engineer with over 30 years experience in gear manufacturing.  Expertise includes both domestic and international plant start-up, and the purchase, runoff and oversight of installation of new equipment.  Excellent statistical problem solving background.  Proven ability to provide training at all levels of the organization.  Possess strong computer, presentation, coaching and interpersonal skills.


Select Accomplishments

1. Authored technical paper "Using Gear Cutting Tool Inspection to Improve Gear Quality" which was published by SME in October 1994.
2. Participated as a speaker at an SME seminar "Understanding Gear Metrology", November 1994, Fort Mitchel KY.  Delivered a presentation on Hob Cutting Tool Inspection and the relationship of cutter features to characteristics produced on the gear.
3. Presented with the "People Make Quality Happen" award in 2001, as part of the Allison Transmission Gear Noise Reduction Team.
4. Assisted Tennessee Department of Education in development and validation of three competency-based training classes in quality control.
5. Developed a course in cutter grind technology.
6. Developed four competency-based training classes in gear cutting technology:
        * Gear Terminology
        * Gear Measurement Methods and Analysis
        * Gear Manufacturing Problem Analysis
        * Gear Quality Improvement


Professional Experience

General Motors Corporation  1978 - 2008    (Early Retirement 01 Nov 2008)
GM Powertrain, Pontiac, MI.
Program Systems Engineer - Manufacturing, 2007 - 2008
Acted as key interface between Product Management Team, Design Responsible Engineers, Design System Engineers and Manufacturing Engineers for GF-6 Transmission.
    1. Ensured product designs are optimised for the manufacturing system.
    2. Led resolution of system issues impacting manufacturing.
    3. Managed and communicated product requirements/changes which impact manufacturing.
    4. Championed the Bill of Process and Bill of Equipment at manufacturing sites.
    5. Tracked the implementation of process changes across sites, to ensure global commonality.
    6. Approved product designs utilizing the Engineering Work Order process.
    7. Made presentations of engineering changes, impacting manufacturing, to the Change Review Board and act as the voice of manufacturing to the Program Execution Team.

General Motors Corporation
GM Powertrain, Ypsilanti, MI.
Global Lead Manufacturing Engineer for GF-6 Transmission,  2004 - 2007
    1. Supported plant start-up for gear manufacturing in USA, Korea, China and Mexico.
    2. Manufacturing Release Engineer for GF-6 Transmission, Gears and Carriers.
    3. Manufacturing Technical Liaison with Product Engineering for GF-6.
    4. Consultant to GM Daewoo Manufacturing Engineers for plant start-up in Boryeong, S. Korea
    5. Provided technical support for GF-6 in China.

GM Allison Transmission, Baltimore, Maryland.
Lead Gear Manufacturing Engineer, 1999 - 2004
    1. Responsible for new plant start-up of gear manufacturing and heat treatment.
    2. Commissioned Atmosphere Carburizing furnaces and Nitriding furnaces.
    3. Coached new Manufacturing Engineers.
    4. Developed and directed Tool Commodity Manager.
    5. Implemented Cost Per Unit cutting tool contracts.
    6. Supervised Metallurgical Lab and managed Drawing Change Control.

GM Allison Transmission, Indianapolis, Indiana
Senior Tool and Gear Development Engineer, 1992 - 1999
    1. Held responsibility for improving gear quality and productivity throughout Allison plants, including gear cutting tool design and machine efficiency.
    2. Developed and conducted training for gear manufacturing skills improvement for Manufacturing Engineers, Cutter Grind Technicians, Machine Setup and Production Operators, and Inspectors of gears and gear cutting tools.
    3. Acted as liaison between Product Design and Gear Manufacturing.

GM Saturn Corporation, Spring Hill, Tennessee
Manufacturing Engineer/Quality Engineer,  1990 - 1992
UAW Quality Coordinator, Engines and Transmissions 1989 - 1990
Charter Team Member, Gears and Shafts  1988 - 1989


Allison Transmission, Indianapolis, Indiana
Problem Solving Team Coordinator, 1985 - 1988
Production Supervisor,  1984 - 1985
SPC Coordinator,  1982 - 1984
Production Machinist,  1978 - 1982


Professional Development

1. Three week "Institute for Productivity Through Quality", University of Tennessee, Knoxville, TN (statistical problem solving)
2. 40-hour course on "Training the Trainer", Owen Graduate School of Management, Vanderbilt University, Nashville TN.
3. 40-hour "Pro-Trainer" course by GM Education and Training.
4. 40-hour seminar "Methods for Management of Productivity and Quality", by Dr. Edwards Demming.
5. Design of Experiments and Tagguchi methods.
6. Advanced training in SPC and Statistical Problem Solving.
7. Various GM Training classes, including Root Cause Analysis, Manufacturing Systems Qualification, Targets for Excellence, Process Control Plan, Concepts of Variation, Failure Mode and Effects Analysis, Compliance Overview, as well as numerous people skills and team building courses.