Paul Sorvari
Osceola
Summary
Results-driven engineering manager adept at executing capital expenditure programs and leading continuous improvement efforts. Combines deep technical knowledge with strong leadership abilities to effectively manage projects, ensuring compliance and delivering innovative solutions that meet evolving market demands.
Overview
29
29
years of professional experience
1
1
Certification
Work History
Program Manager
PSI Molded Plastics
South Bend
06.2025 - Current
- Program Manager leading new business activities and process improvements for the Engineering Department
- Managed engineering program operations to ensure timely project delivery and adherence to quality standards
- Coordinated engineering program management activities for capital expenditure initiatives, enhancing resource allocation and project alignment
- Engineering lead for new customer-facing programs
- Collaborated with sales team to support new quoting opportunities, streamlining communication and improving proposal accuracy
- Led continuous improvement initiatives
- Lead for all prototype and pre-production build events
- Project Feasibility development and analysis
Engineering Program Manager
OPmobility (formerly Plastic Omnium)
Elkhart
01.2024 - 06.2025
- Engineering Program Management activities for new and existing Capital Expenditure Battery programs
- Primary Engineering contact for all customer-facing Battery programs
- Led new and VA-VE Capex electrification initiatives for e-Power Organization, enhancing project alignment with strategic goals.
- WePRO Product Development Phase Gate procedure (APQP) management within the INPRO.net PLM
- WeCHANGE Product and Process change procedure (ECR-ECO) within the INPRO.net PLM
- Project Feasibility analysis using StopINvest, Go/No Go metrics with Sales Organization collaboration.
- Leading Continuous Improvement (CI) initiatives within the Engineering Department
- Oversaw testing validation, product qualification, and manufacturing test requirements, ensuring compliance with industry standards.
- Manufacturing lead for all prototype and production build events
- Developed new APQP processes and documentation to streamline project execution and enhance quality assurance.
- FMVSS, and ISO regulatory compliance management
Engineering Manager
Dexstar Wheel
Elkhart
12.2022 - 01.2024
- Engineering Manager leading new, sustaining, and cost reduction initiatives for the Dexstar Wheel Organization
- Managed engineering activities for new and existing capital expenditure projects, ensuring alignment with organizational goals.
- Coordinated resources of all engineering personnel to support project activities, optimizing team deployment.
- Leading Continuous Improvement (CI) initiatives within the Engineering Department.
- Primary Engineering contact for all customer-facing programs
- Direct Engineering contact for all testing and product qualification activities
- Engineering Change Notice (ECN) implementation and management
- Engineering Feasibility analysis and collaboration with the Finance and Sales Departments
- ISO 9001: 2015 documentation development and support
- Facilitated daily collaboration with interdepartmental stakeholders: finance, maintenance, production operations, purchasing, quality, safety, and sales.
Project Manager
ACTIA Corporation
Elkhart
08.2020 - 11.2022
- Project Manager leading both new and sustaining initiatives within the ACTIA US and ACTIA Power Business Units.
- Project Management position in the Engineering Organization that leads customer-facing programs.
- Project Lead for both Commercial Vehicle and Battery application programs
- Conducted project feasibility analysis in collaboration with Sales Organization to assess project viability.
- Managed Jira for Agile team to streamline issue tracking and enhance project visibility.
- Developed new APQP processes and documentation to improve product quality and compliance.
- Management of functional specification, testing validation, and manufacturing test requirements
- Manufacturing lead for all prototype and production build events
- Lean Manufacturing production support
- FMVSS, and ISO regulatory compliance management
- Engineering Team Lead Management
Program Manager
CTS Corporation
Elkhart
11.2016 - 08.2020
- Program Manager leading new and sustaining initiatives within the Sensors and Mechatronics Organization.
- Led project team to ensure safe launch by meeting customer quality and delivery expectations throughout product development cycle.
- Managed budget for new capital expenditure programs and sustained value-analysis/value engineering (VA-VE) initiatives.
- Managed APQP phase-gate deliverables for all capital expenditure programs.
- Program Timeline Milestone and WBS development and maintenance using MS Project 2013.
- Supporting customer quotation development and cost analysis activities
- APQP Documentation review and approval using Team Center V 10.0 PLM Software
- Coordination with both internal departments and external suppliers to support new assembly line development.
Senior Engineer
Whirlpool Corporation
Saint Joseph
01.2015 - 11.2016
- Senior Engineer leading new project development initiatives for the Vertical Axis (VA) Laundry Organization.
- Lead Engineer on Advanced Development, and new Product Development Programs
- Coordinated cross-functional teams to ensure timely delivery of program and project milestones
- Program Launch Engineer for the Washer Lid and Dryer Door Sub-Systems
- Executed Change Notice (CN) activities to facilitate new and sustaining development programs
- Supported part quality and engineering test development as manufacturing liaison and PPAP engineer
- Product Data Management (PDM) documentation development and training support using Windchill 10.2 PDMLink
Program Manager
AmSafe, Inc./Shield Restraint Systems, Inc.
Elkhart
09.2010 - 09.2014
- Program Manager and Project Engineer leading new project and VA-VE initiatives for the Specialty Vehicle Segment.
- Coordinated cross-functional teams for program and project activities and deliverables.
- Concept to Production (CTP) Gate Review Manager responsible for directing, conducting, and auditing monthly reviews required for all budgeted programs and projects.
- Developed and maintained program timeline milestones and WBS using MS Project 2007.
- Developed and improved processes for new and existing ISO documentation.
- Product Development, Sustaining Engineering, and Engineering Change Notice (ECN) activities using Solid Works 2013 and AutoCAD 2008 LT
- FMVSS, CMVSS, SAE, and ECE standard testing compliance and coordination
- Test development, support, and report documentation activities.
- Coordination and support with quality, internal/external sales, supply chain management, and suppliers
Design Engineer
Morgan Olson
Sturgis
01.2010 - 07.2010
- Developed a zero-emission electric fleet delivery truck body on a Smith Electric Chassis
- Stress and deflection calculations performed on innovative design concepts.
- Component, assembly, and installation layout development using UG NX5.
- Led new product development programs and resolved sustaining production issues, ensuring alignment with project timelines and quality standards.
- Engineering Change Order (ECO) design and routing activities, BOM development and part management using JD Edwards E1 MRP software.
- Provided pilot and production manufacturing support to resolve engineering change request (ECR) issues at two assembly plants, delivering daily floor support for urgent assembly (PPS board) challenges.
- Delegated design tasks to engineering staff.
- Pareto and bar chart analysis using Minitab V15 for both internal and warranty defect data.
- Coordinated sales and purchasing processes with suppliers, facilitating timely project delivery through effective communication and collaboration.
Product Design Engineer
GulfTran, LLC.
Nappanee
08.2009 - 12.2009
- Engineering Lead developing multiple bus platforms for a new shuttle bus division.
- Lead engineer accountable for the structural/mechanical system design of the GulfTran bus product.
- Conducted packaging studies for frame, bus body structure, HVAC system, and rear bumper, optimizing design integration.
- Delegated engineering design tasks to subordinate staff, ensuring project alignment with design objectives.
- Part design and layout analysis using Inventor 2008; Bus floor plan layout using AutoCAD 2009.
- Provided engineering support to manufacturing, sales, purchasing, and supplier teams, facilitating cross-functional collaboration.
- FVMVSS/CMVSS prototype testing/Altoona Bus Research and Testing Center coordination
Chassis Project Engineer
Monaco Coach Corporation
Elkhart
02.2008 - 05.2009
- Led new product development projects for coach and chassis divisions, ensuring alignment with engineering standards.
- Project Engineering Lead for both front and rear engine chassis products
- Part design, detail drawing, assembly, and layout development using UGNX4.
- System and Component-level Finite Element Analysis using FEMAP V10.
- Engineering Change Review and release activities using Team Center V9
- Developed BOM and managed part number creation for streamlined project execution.
- Collaborated with Purchasing, Manufacturing, and Supplier teams to facilitate project requirements and enhance product integration.
Project Engineer
International Truck & Engine Corporation (Navistar)
Fort Wayne
05.1998 - 02.2008
- Engineering Lead completing new product development, federal engine emission, VA-VE, and warranty initiatives for the Chassis and Body System Engineering Departments.
- Project Engineering, serving as the engineering lead on major programs since 2002.
- Project Engineer in Chassis Systems, Frame and Fuel (2004 – 2008)
- New product development Programs (e.g., 2007 EPA Engine Program, NGV 8600)
- Warranty Claim, Business Cost Reduction, and Supplier Transition Programs
- Interfaced with customer, purchasing, manufacturing, and reliability cross-functional teams to align project objectives and requirements.
- Delegated work to subordinate engineering personnel on major program activities to ensure project milestones were met.
- Communicated program status and timing to upper management to facilitate informed decision-making.
- Chassis and Body system design and packaging layout activities
- Conceptual part design, detail drawing, assembly, and layout development using UGNX4.
- Component-level Finite Element Analysis using MSC/Acumen.
- Engineering Release and Product Structure (Bill of Material) Development with TC V9
- Geometric Dimensioning and Tolerancing (GD&T) and linear tolerance stack-up analysis
- DFMEA documentation development and maintenance
- Statistical tolerance analysis of manufacturing part data to determine root cause.
- FMVSS/CMVSS/FMCSR Judgment document compliance
- Ergonomic analysis of the cab structure’s interior using SAE ground vehicle standards
- Associate Project Engineer in Body Systems, Interiors and Body Exteriors (1998 - 2003)
Project Engineer
Aeroquip Corporation (Danfoss Power Solutions)
Van Wert
07.1997 - 02.1998
- Project Engineer, Advanced Manufacturing Engineering Group
- Designed and implemented semi-automated assembly cells and developed assembly tools and fixtures to streamline operations.
- Supported development of manufacturing assembly cells for new product launches, enhancing production readiness.
- Conducted takt time studies and QC gauging studies at CNC machining stations.
Education
Master of Science - Engineering Management
Indiana Institute of Technology
Fort Wayne, IN02-2009
Master of Science - Business Administration
Indiana Institute of Technology
Fort Wayne, IN11-2003
Bachelor of Science - Mechanical Engineering, Mechanical Engineering Technology
Lake Superior State University
Sault Ste. Marie, MI05-1997
Associate of Applied Science - Mechanical Design Engineering Technology
Michigan Technological University
Houghton, MI05-1994
Skills
- Capital Expenditure Program Management
- Engineering Team Management
- APQP Development and Management
- PPAP/FAI Management
- Statistical analysis
- Six Sigma Methodology
- Lean Manufacturing
- DFMEA
- Tolerance stack-up analysis
- Vehicle Weight Center of Gravity (CG) analysis
- FEA Stress analysis (FEMAP V10)
- Stress-strain calculations
- 3D modeling
- 2D Detailing
- GD&T
- Manufacturing Process methods
- Customer Quote Analysis and Development
- Tool, Jig and Fixture design
- BOM development and management
- Engineering Test development
- AutoCAD 2023
- INPROnet PLM
- Windchill PDMLink
- Team Center (TC) 2018
- SAP 2022
- DELMIAWorks (IQMS) 2022
- Minitab V22
- Jira Software 2020
- SAGE 100 2023
- MS 365 Project Professional
- MS 365 Visio
- MS 365 Office Suite
- ISO 9001: 2015 audit support
- IATF16949: 2016
- Sheet metal design
- Stampings
- Extrusions
- Plastics
- ISO 9001: 2015 audit support
Affiliations
- ASEM
- ASME
- ASM
- PMI
- SAE
- SME
- Current ASME St. Joseph Valley Chair
- Previous SME Chapter 30 South Bend Chair
- Ratio Professional Group, Inc. – Board of Advisor (BoA) Member
Certification
- Certified as an Engineering Intern (EI) in the State of Michigan
- Certified as a Manufacturing Engineer (CMfgE) by the Society of Manufacturing Engineers
- Certified as a Manufacturing Technologist (CMfgT) by the Society of Manufacturing Engineers
- Certified as a Six Sigma Green Belt in 1999 through the Navistar Six Sigma Certification Program
- Certified as a Level 2 Welding Inspector by the CWB Group in 2023
Patents
- 6,640,918, Hood Mounting System for Mobile Vehicle, 2003
- 7,651,133, Frame Extender, 2010
Timeline
Program Manager
PSI Molded Plastics
06.2025 - Current
Engineering Program Manager
OPmobility (formerly Plastic Omnium)
01.2024 - 06.2025
Engineering Manager
Dexstar Wheel
12.2022 - 01.2024
Project Manager
ACTIA Corporation
08.2020 - 11.2022
Program Manager
CTS Corporation
11.2016 - 08.2020
Senior Engineer
Whirlpool Corporation
01.2015 - 11.2016
Program Manager
AmSafe, Inc./Shield Restraint Systems, Inc.
09.2010 - 09.2014
Design Engineer
Morgan Olson
01.2010 - 07.2010
Product Design Engineer
GulfTran, LLC.
08.2009 - 12.2009
Chassis Project Engineer
Monaco Coach Corporation
02.2008 - 05.2009
Project Engineer
International Truck & Engine Corporation (Navistar)
05.1998 - 02.2008
Project Engineer
Aeroquip Corporation (Danfoss Power Solutions)
07.1997 - 02.1998
Master of Science - Engineering Management
Indiana Institute of Technology
Master of Science - Business Administration
Indiana Institute of Technology
Bachelor of Science - Mechanical Engineering, Mechanical Engineering Technology
Lake Superior State University
Associate of Applied Science - Mechanical Design Engineering Technology
Michigan Technological University