Stephen Sattler

Stephen is a Senior Advisor with FTE Performance Consulting whose career spans over 30 years across manufacturing, operations, engineering, and quality in the automotive and off-highway fuel system industries.  Working at multiple manufacturing centers, Stephen has consistently demonstrated his ability to lead organizations through complex situations to deliver safety, cost, quality, and schedule improvements. He has experience in all aspects of automotive manufacturing, with progressive leadership roles in body assembly and welding, paint operations, and general assembly. In addition, Stephen has led both the engineering and quality systems organizations for a leading global manufacturer’s diesel fuel systems facility.

Notable experience and accomplishments:

  • Managed multi-site operations of key fuel systems components.  Developed and executed the master plan for the consolidation of operations to one manufacturing center. CNC machining and assembly equipment were shut down, relocated, and requalified with no customer impact and 45% reduction in labor cost. 
  • Transformed manufacturing structure with the implementation of a team-based culture by selecting, training, and empowering team leaders to support production schedule attainment,  process improvement initiatives, and prototype development.   Leveraged the team-based structure to introduce business plan deployment thorough the entire organization, with team leaders responsible for safety, quality, schedule and cost metrics.
  • Reduced annual warranty and repair costs by over $600,000 annually by translating JD Power and voice of customer data to modify process control plans and revise operator standardized work.
  • Reduced warranty DPU by over 90% on a key Tier 4 fuel injection component by leading technical discussions with customer engineering and quality resources to identify critical performance features, develop validation testing, and inspection correlation studies.  
  • Led the product launch for non-OEM replacement fuel system.  Project included specification development, performance validation, manufacturing process development and product launch.   Additional activities include capital equipment planning and procurement to support current and future volumes with the potential for 25% facility revenue growth.
  • Implemented Paint Shop throughput improvement plan to support a 40% planned schedule increase.  Major equipment rebuild  to increase MTBF and reduce MTTR achieved  through reprocessing and equipment exchanges for offline repair with no extended plant shutdown required for equipment and process changes 

Stephen is a certified Project Management Professional (PMP) and holds a Master of Science Degree in Engineering Science from Rensselaer Polytechnic Institute and a Bachelor of Science Degree in Mechanical Engineering from GMI Engineering and Management Institute (now Kettering University).