Wally Sahlani
Professional Engineer
Toronto,Ontario
Summary
Experienced professional engineer with over 20 years of expertise in program management, field service, and process optimization. Proven track record of leading multimillion-dollar projects, achieving $275K in cost savings, 25% efficiency gains, and a significant 60% reduction in downtime using Six Sigma and Lean Manufacturing methodologies.
Overview
26
26
years of professional experience
5
5
Certifications
Work History
Technical Engineering Consultant
S E Enterprises INC
Brampton, Ontario
07.2024 - Current
- Spearheaded the integration of remote patient monitoring and respiratory support systems, streamlining workflows and reducing operational costs by 15%
- Championed the planning, installation, and preventive maintenance of critical medical devices, improving efficiency by 25%
Field Service Manager
Webasto Roof Systems (at Ford Motor Company)
Oakville, Ontario
07.2008 - 06.2024
- Company Overview: Automotive Roof Systems
- Delivered $275K in cost savings by reducing variation in service processes through Six Sigma initiatives
- Oversaw end-to-end technical service operations and led four product launches by mitigating pre-production risks and optimizing rollout schedules
- Mentored 30 technicians, serving as a liaison and technical expert, integrating industry best practices that elevated first-time fix rates by 17% and minimized repeat visits
- Diagnosed and resolved malfunctions, reducing downtime by 60% and boosting productivity by 10%
- Analyzed warranty claims data, identified root causes, and executed cost-effective countermeasures, saving $41K annually
- Compiled detailed post-service technical documentation, reported key findings, troubleshooting procedures, and solutions, reducing client follow-ups by 43% and securing 90% positive feedback
- Automotive Roof Systems
Program Manager
Metalforming Technologies
Toronto, Ontario
11.2004 - 05.2008
- Company Overview: Metal Stamping
- Enhanced metal stamping efficiency through lean principles, cutting costs by 25% and reducing reject rates by 10%
- Cut emergency repair expenses by $40K annually through KPI-driven preventive maintenance and quality control tracking
- Directed cross-site projects ahead of schedule while exceeding performance targets by 20% through effective team leadership
- Increased on-time delivery by 25% by synchronizing project schedules with updated Bill of Materials (BOM) structures
- Metal Stamping
Project Manager
Dana Corporation
Oakville, Ontario
12.2001 - 11.2004
- Company Overview: Heat Exchangers
- Managed $2.5M+ engineering projects, ensuring adherence to scope, budget, and timelines
- Executed the APQP process from concept design to production, ensuring the timely delivery of high-quality product launches
- Streamlined material sourcing by identifying inefficiencies and negotiating supplier contracts, resulting in $140K annual savings
- Overhauled outdated production tools, integrating improvements that reduced runtime by 40%
- Heat Exchangers
Process / Quality Engineer
Progressive Molded Products
Toronto, Ontario
04.1999 - 11.2001
- Company Overview: Injection Molding
- Initiated changes to Key Product & Control Characteristic, gauges, and continuous improvement activities, achieving a 15% reduction in cycle time
- Developed FMEA and Process Flow Diagrams, decreasing process delays by 25% and enhancing product quality by 20%
- Injection Molding
Education
Bachelor of Engineering - Mechanical Engineering
Toronto Metropolitan University
Toronto, OntarioWebsites
Certification
Licensed Professional Engineer P.Eng, Professional Engineers of Ontario
Training And Development
- PMP - Exam Prep Seminar, Udemy
- The Complete Hydraulic Course, Udemy
- HVAC Fundamentals & BMS Controls, Udemy
- Rotating Equipment: Pumps & Compressors, Udemy
- Motor Starter Circuits, Udemy
- Basic Pneumatic Technology, Parker
- Electrical Systems, Reading Drawings & Schematics, LinkedIn Learning
- Lean Manufacturing, Len Jacobs Management Services
- Geometric Dimensioning & Tolerance, Center for Statistics in Industry
- Financial Planning for Business Success, Dana University
- Product Cost Analysis, Dana University
- Personal Strengths for Effective Managing, Dana University
- Supervisory Skills to get Results, Dana University
- 8D-Problem Solving, Magna
- Design & develop of Engine Cooling Systems, University Consortium for Continuous Education
- Compact Heat Exchangers, Society of Automotive Engineers
- Product Design with Aluminum Alloys, Society of Automotive Engineers
Skills
Six Sigma, Preventive Maintenance, Root Cause Analysis, Lean Manufacturing, Quality Assurance Compliance, Blueprint & Schematic Interpretation, Cross-Functional Team Coordination, Continuous Improvement, Process Optimization, Project Management, Communication & Organizational Skills, AutoCAD, SolidWorks, FMEA, APQP, GD&T, Microsoft Office
Timeline
Technical Engineering Consultant
S E Enterprises INC
07.2024 - Current
Field Service Manager
Webasto Roof Systems (at Ford Motor Company)
07.2008 - 06.2024
Program Manager
Metalforming Technologies
11.2004 - 05.2008
Project Manager
Dana Corporation
12.2001 - 11.2004
Process / Quality Engineer
Progressive Molded Products
04.1999 - 11.2001
Bachelor of Engineering - Mechanical Engineering
Toronto Metropolitan University
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