Matt DeBusk is a Program Manager with FTE Performance Consulting with 25 years of experience in project management, including new model introductions, advanced manufacturing, industrial engineering, facilities management, maintenance, quality systems, and Information Technology (IT). Matt has coordinated the startup of 18 Tier 1 automotive programs and 2 CA-based EV launches utilizing just-in-time (JIT) sequencing and lean methodologies. He has led both large and small teams, engaging in activities such as financial forecasting, launch planning, structured problem-solving, output acceleration, and corporate strategy development. Matt has a reputation for always executing projects on-time and within the approved budget.

Notable experience and accomplishments:

  • Recruited and mentored internal team leaders to serve in lean manufacturing apprentice-type roles on a 6-month rotational basis, ultimately identifying and closing more than 300 labor saving opportunities.
  • Reduced the hours required to assemble a vehicle (HPV) by 42% within 6 months by implementing Kaizen initiatives throughout an electric vehicle (EV) manufacturing facility.
  • Created and led a 10-person Advanced Manufacturing & Electrical Engineering team to support the General Assembly operations.
  • Formally recognized by Tesla for “Excellent Quality Performance” in June 2012.
  • Deployed $100M in productive assembly capital throughout North America, creating over 7,000 total positions.
  • Earned U.S. Patent #6,832,503 for developing a new end-of-line passenger seat calibration system, enabling smart airbag technology.
  • Executed manufacturing change-overs to supply high-volume JIT seating to General Motors, Ford, and FCA operations.
  • Launched a joint-venture operation (Reyes Automotive Group) supplying JIT interior / exterior trim and carpets for the new Toyota Tundra campus in San Antonio, TX.

Prior to consulting, Matt held high-responsibility roles at Lear Corporation, Faurecia Automotive Seating, Futuris Automotive, and Karma Automotive. Some of his previous titles include: Industrial Engineering Manager, Launch Manager, Technical / Quality Manager, Advanced Operations Manager – Americas, Advanced Manufacturing Manager – General Assembly, and Productivity Manager – KICC.

Matt initiated his education at GMI Engineering & Management Institute and began his career in a co-op engineering role. He later graduated from Walsh College and holds a Bachelor’s of Business Administration – Finance degree. Matt has also attended Six Sigma Blackbelt training, hosted by the Six Sigma Academy in Paris, France in 2009.

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