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CHAD NESTELL OPERATIONS•MANUFACTURING QUALITY•PROJECT LEADERSHIP PEOPLE|PROCESS|PROGRESS
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Current Business

Founder | Director of Training & Operations

Applied Response Training LLC

Jul 2026 – Present

Founded and lead a veteran-owned safety training business built around practical emergency-response education and disciplined operating systems.

  • Established the organization as an American Red Cross Licensed Training Provider for First Aid, CPR, and AED training
  • Developed the operating model for public classes and on-site group training, including pricing, scheduling, venues, registration, equipment, documentation, and customer follow-up
  • Designed and maintain the company website and a custom training-management portal supporting class administration, personnel, finance, document control, and operational tracking
  • Standardized class-preparation, delivery, closeout, and recordkeeping workflows to support consistent training operations
  • Lead expansion planning for BLS, workplace safety training, and broader safety-consulting services
Applied Response Training — About Chad Nestell ↗
Current Role

Process Engineer

Amigo Mobility International

Mar, 2025 - Present
  • Work with production personnel to identify manufacturing and assembly constraints, then develop practical solutions involving process changes, tooling, fixtures, equipment, and workflow
  • Develop production tooling, fixtures, and process aids from concept through implementation, including CAD modeling, detailing, fabrication support, and shop-floor validation
  • Create detailed, CAD-based work instructions and visual documentation that translate manufacturing requirements into clear, repeatable production methods, reducing variation and improving consistency on the shop floor
  • Support new manufacturing processes through hands-on implementation, troubleshooting, and operator training, ensuring new work is proven and standardized before transitioning to production
  • Bridge engineering requirements and production needs by coordinating with engineering, quality, and shop-floor personnel to resolve manufacturing issues and implement workable process changes
Major Project

Wire Harness Vertical Integration

Led the vertical integration of wire harness assembly from external sourcing to in-house production, developing the equipment, tooling, production cell, documentation, testing methods, and training required to support production

  • Designed and established a dedicated wire-harness production cell with six terminal presses maintained in unique terminal configurations, automated wire cutting/stripping equipment, and assembly stations to support repeatable production with minimal changeover
  • Designed and fabricated custom benches, wire-payoff systems, and assembly workstations tailored to the equipment, material flow, and operator requirements of the new production cell
  • Created detailed visual work instructions for each wire and harness configuration, documenting equipment setup, assembly sequence, terminal requirements, and inspection criteria to support repeatable production and operator training
  • Designed and implemented in-process inspection fixtures for wire-harness production, shifting quality verification into the manufacturing process and eliminating the need for separate final inspection
  • Developed and validated the production-capacity model for in-house wire-harness manufacturing, analyzing demand, cycle times, staffing, equipment loading, production methods, and implementation priorities to provide Operations with a complete plan for ongoing production
  • Qualify each new wire and harness configuration before production release, establishing the manufacturing method and training operators on the required equipment, tooling, inspection criteria, and assembly process
Quality / Technical

Quality Testing Associate | Test Lab Lead

Amigo Mobility International

Sept, 2024 - Mar, 2025
  • Served as the primary point of contact for product testing across the organization, determining the appropriate approach for both established requirements and unique testing needs
  • Designed and fabricated test fixtures and developed mechanical and electrical test methods for product performance and specialized evaluation needs, including work performed to established ANSI and UL standards
  • Developed a standardized visual test-documentation system using detailed technical line illustrations to define test setup, fixtures, procedures, acceptance criteria, and results in consistent, repeatable test packages
  • Established performance baselines for current components and used comparative testing to qualify alternate supplier parts before production approval
  • Analyzed test data to identify failure modes, troubleshoot product issues, and work with engineering and production teams to validate corrective actions

Mobility Sales Consultant

Amigo Mobility International

Dec, 2020 - Sept, 2024
  • Consistently exceeded quarterly sales targets, tracking performance against defined goals and submitting regular sales metrics to management
  • Increased referral business by 21% by developing and maintaining relationships with healthcare providers, therapists, and rehabilitation centers
  • Used an application-based sales approach to match mobility products to customer needs, operating environment, and intended use rather than relying on a one-size-fits-all product recommendation
  • Translated technical product features—including controls, power systems, safety features, and operating capabilities—into practical information customers and referral partners could readily understand
  • Conducted product demonstrations and technical training for customers and referral partners, supporting product selection, safe use, and long-term customer confidence
  • Served as a technical-commercial link between customer requirements and product capabilities, helping identify workable mobility solutions when needs were more complex than a standard product selection

Technical Sales / Product Support

JCL Snowplow Dealer, Inc.

Sept, 2017 - Dec, 2020

Commercial equipment dealer supporting municipal and commercial operations through application-specific trailer design, vehicle integration, and custom equipment solutions.

  • Managed technical sales for trailers, snowplows, and commercial equipment, improving product positioning and application-based sales
  • Designed and configured custom trailer systems for commercial and municipal use, including high-load and confined space applications (City of Detroit)
  • Developed mounting brackets and integration solutions for snowplow installations on non-standard and specialized vehicles
  • Designed equipment racks, holders, and support systems for lawn and service vehicles based on real-world use requirements
  • Enhanced vehicle functionality through integrated lighting, tooling storage, and application-specific configurations
  • Implemented digital and in-store marketing strategies to maintain pricing integrity and improve product visibility
  • Developed and maintained company website, including SEO and e-commerce functionality
  • Built supporting database structure for e-commerce and maintained search rankings for key product categories

Owner | Project Manager | Site Developer

Spider’s Domain Web Design

Includes concurrent roles

Jan, 2014 — Sept, 2017
  • Specialized in performing content maintenance, site structure repair, and SEO for small and medium size business websites, non-profit organizations, and individual / family sites
  • Re-designed existing websites, giving them a cleaner and more modern look and feel using the latest standards
  • Re-fitted and re-designed static sites for dynamic and responsive (mobile) content
  • Added server side scripted functionality to sites where dynamic content interaction was needed
Leadership Experience

Operations Manager

Frankenmuth Clock Company

Dec, 2012 — Dec, 2013
  • Managed all operational aspects of a retail business, including marketing, business model adjustments, facility maintenance, personnel hiring and training, merchandise acquisition (including importing), inventory management, and clock repair
  • Provided strategic direction and supervision to the floor manager, ensuring alignment with current company objectives
  • Reconciled books daily, updated databases, managed budgets, and ensured compliance with tax and legal requirements
  • Managed payroll processing and employee scheduling
  • Developed and implemented data systems to categorize, analyze, and forecast sales trends
  • Coordinated with vendors and suppliers to streamline procurement and maintain optimal stock levels
Career Highlight

Sr. Sales Engineer - Coordinator (Manager)

Obara Corporation USA

Sept, 2003 — Dec, 2012

Managed automotive robotic resistance welding accounts for OEMs, system integrators, and Tier 1 suppliers, supporting body shop applications through technical coordination, consumable design, pricing, forecasting, and launch support. Key programs included Ford S197, P221, U251, P415, D219, D258, and CD338 (Aguascalientes, MX).

  • Managed multi-million dollar robotic welding accounts for Ford, Nissan, Hyundai, Mitsubishi, Kia, Mazda, General Motors, integrators, and Tier 1 suppliers
  • Supported major automotive launch programs by coordinating weld gun applications, consumables, pricing, spare parts, and delivery priorities
  • Designed and specified robotic resistance welding consumables, including electrode caps, shanks, holders, adapters, and copper wear components
  • Developed monthly and long-range forecasts to support production, purchasing, and financial planning
  • Established and maintained pricing based on copper costs, manufacturing methods, labor, market conditions, and competitor activity
  • Developed internal database tools and SQL-based reporting to support sales, production, and financial operations
  • Established and maintained the division’s IT network and relational database environment for approximately 20 workstations
  • Helped develop the U.S. division’s website and online spare parts database
  • Built reports for sales, financial, and production teams
  • Automated operational documents, forms, and data processes
  • Improved data organization, tracking, and reporting efficiency

Production Control

Obara Corporation USA

1999 — Sept, 2003

Managed production planning and manufacturing support activities spanning BOMs, routings, material requirements, process planning, scheduling, CNC programming, tooling, and shop-floor production support.

  • Created bills of material and manufacturing routings, defining operation sequences, equipment requirements, and production methods
  • Calculated raw-material requirements for bar, coil, and plate stock based on part geometry, manufacturing method, and expected usage
  • Developed manufacturing process plans, determining machining requirements, process flow, and estimated setup and run times
  • Created and maintained production schedules while supporting job tracking, production visibility, and manufacturing priorities
Technical Production Support

Manufacturing & Process Development

  • Programmed CNC equipment using Fanuc and Yasnac controls and developed waterjet nesting layouts, lathe taper diagrams, and bending plans used in production
  • Supported tooling and process development, including design work for five- and six-progression cold-heading dies, jigs, fixtures, and specialized production equipment
  • Developed database-driven tools and reporting used to track production activity and operator efficiency
  • Provided direct shop-floor support during staffing shortages, including CNC programming, receiving and final inspection, and operation of vertical mills and engine lathes

Lead Assembly Technician / CAD Designer

Key Transducers, Inc.

1998 — 1999
  • Performed complete assembly and testing of both load cell and rotary transformer torque transducers. Assembly techniques included material and mechanical testing, precision soldering and measurement skills, “clean” installation practices, and the accurate mixing, application and curing of adhesives. Rotary units required precise bearing installation, greasing, and spin testing/break-in.
  • Developed illustrated instructional manuals and specific job function diagrams to standardize company assembly and calibration techniques.
  • Assisted in final calibration using a demodulator, voltmeter, and calibrated weights. Monitored output signals using an oscilloscope.
  • Aided in the CAD design and modeling of new products and applications. Modeled existing products in multiple native CAD languages for engineering use by potential customers (in order to easily incorporate our products into their designs)
  • Traveled with sales staff to provide technical and design implementation support when establishing new accounts.