Mansoor Chaudhry

***** ******** *****, ******, **, 48187 810-***-**** acvfp6@r.postjobfree.com

Employment History

IAC – Springfield, TN, Senior Engineer/(Program Manager) (Jun 2014 – Nov 2015)

Managed Launch of Carpet and Non Carpet Flooring and Dash Insulators for GM Programs (31XX, K2XX and GMX211), 60 Million Dollars business at IAC Springfield, TN. Manufacturing Processes include Thermoforming, Insert Foam Molding, Die Cutting, Water Jet and Sonic Welding.

Performed PFMEA, 5S, KAIZEN, Audits, Teardowns, Costing, Development of Tools, Assembly Plant Visits and Directed Prototype Parts Manufacturing.

Ran Mold Trials to select PolyOne PVC as back up material for K2XX and 31XX Dash Insulators.

Improved production of K2XX Dash Insulators over 30% by removing bottlenecks in maximizing the production.

Also improved relationships with GM Assembly Plants by providing excellent services.

Successfully implemented engineering changes for K2XX and 31XX Carpet/Vinyl Floors and Dash Insulators.

Knowledge of Software PLM, AS400, GM SupplyPower and Prolink and wrote ECNs and Work Orders(WOs)

Chrysler/Ford, Overhead System Engineer/ Design and Release Engineer (May 2013 – Mar 2014)

Contract; Employer G-Tech, Dearborn, MI

Responsible to Design, Release, Solve Product Quality Issues and Reduce Warranty Claims for 2014 Jeep Cherokee Overhead System.

Worked on Technical Cost Reductions projects of over $1.5 Million related to HIC, BSR and NVH Foam, Grab Handles, Plastic Retainers in Overhead System, Velcro Hook, One piece Visor Center Support, Sun Visor, Headliner Substrate etc.

Familiar with Control Plans, GD&T, Gage R&R, Process Capability, Measurement Systems and Root Cause Analysis, Successfully use Data to Identify and Resolve Issues.

Also familiar with Chrysler Software eCIMS, CCD, WebCN, FastCAR2, EBOM and Dashboard Anywhere.

Responsible to Design and Release of Deployable Hood Lift Actuators for 2016 MY Mustang, 2015 MY Edge and Galaxy, worked with Full Service Supplier in leading cost reduction ideas. Provided technical directions to Designers and performed Assembly Tolerance Stack up Analysis.

Ford Motor Co., Senior Project Engineer (Nov 2010 – Jan 2013)

Contract; Employer ETA, Troy, MI

Responsible for Design & Release of Carpet, NVH Insulation, Hood Insulation and Cargo Management System for 2013 and 2016MY Ford Explorer.

Worked to resolve related urgent launch issues for 2013MY Ford Escape, Lincoln and Fusion Programs.

Familiar with WERS, CAE, Team Center Engineering, Material and Color Approval Process, QFD, RFQ, BOM, DVP&R, DOE, VA/VE, SPC, APQP, PPAP, ISO9000/TS16949, DFMEA, Six Sigma and experienced to develop a Continuous Improvement Process Flow Chart for Head Impact Protection Countermeasures.

Performed Sled and Component Testing of Safety and Load Carrying Components of FORD Explorer, Taurus, Lincoln and Focus Programs

MCP, Automotive Engineering & Sales Co., Consultant (Jun 2008 – Nov 2010)

Provided Technical Sales and Marketing Support to Fagerdala USA Inc. GECET Worldwide Business.

Provided Design and Development services to Global Enterprises in selection of core foam for JC49 and Chrysler XK Jeep Load Floor Programs.

Worked with Valley Enterprises on Cost Saving Projects for GM Lambda and HHR Load Floor Programs.

GM, Warren Engineering Center, Contract: Aerotek, Troy, MI, Performance Engineer (May 2007 – Jun 2008)

Worked on design/development/testing of Head Impact Protection solutions for GMT900 (Pickup and SUV) Program.

Validated Vehicle Structures and Head Impact Countermeasures for GMX 211 (Impala), GMX245-ZR1 (Corvette) and GMX381(G6) Programs.

Fagerdala USA Inc. Marysville, MI, Product Engineering Manager (Mar 2004 – Mar 2007)

Provided Marketing and technical support to GECET Foam Business in the automotive industry all over the world. The technical support included design, material selection, development, testing, data analysis, quality and safety.

Managed accounts with GM and Draexlmaier providing engineering and commercial support for design, development to launch “Energy Management Foam” applications for passenger knee protection on 2008 CRX program.

Successfully launched GECET “Core Foam Load Floor” for Ford Explorer, Expedition and Mustang programs providing onsite and offsite application engineering support, 2 million dollars business.

Worked with a major Tier 1 on the development of “Head Restraint System” to comply FMVSS202A for an OEM.

Strengthened relationships at OEMs, Tier 1s and molders by providing excellent technical and sales support.

Worked with Lear Corp and JSPI to jointly design EPP Foam Headliner with Energy Management countermeasures for interior Head Impact Protection.

Createc Corporation, Clarkston, MI, Applications Development Engineer (Aug 2002 – Mar 2004)

Opened new accounts at Willis Manufacturing, Casco, Valley Enterprise and Industry Products Company.

Strengthened business relationships at Honda, GM, Ford, DCX, Lear Corp. JCI, Magna, BBI and Midway Products by providing excellent technical and sales support.

Established new contacts at Visteon, Delphi, Grupo Antolin, Draexlmaier, Faurecia, Venture, Azdel, Crotty Corp., Bentler Automotive, Flex-N-Gate, Pullman Industries, Shape Corp., Toshiba, Guardian Automotive, Narmco Group, Lake Side Plastics and NYX Corp.

Huntsman Corp., Auburn Hills, MI, Applications Development Engineer (Sep 1997 – Aug 2002)

Provided marketing and technical support to GECET foam business in auto industry. Successfully marketed GECET foam to Daimler Chrysler RS, JR, AN, DN and KJ platforms for upper interior Head Impact Protection.

Developed two energy management designs that are 40% more efficient than a solid piece of GECET foam.

Tested GECET foam with different designs, thickness and densities. Based on this testing, developed a guideline for the use of GECET foam for Upper Interior Head Impact Protection.

Selected AP-7310-HS as head impact protection Injection Molded PP material for AN Program in 1998. Now sale of AP-7310-HS is more than 2 million dollars and is considered one of the best RTPO in auto industry.

GM & Daimler Chrysler, Contract; Employer ETA, Troy, MI, Project Engineer (May 1995 – Sep 1997)

Worked in Head Impact Protection Group. Familiar with foreign and U. S. safety regulations and test dummies.

Performed Finite Element Analysis using Altair HyperMesh, HyperView and LS-DYNA3D for Head Impact Protection.

Tested vehicles for validation of USA Vehicle Safety Regulations. Tested materials/designs, analyzed test data and made recommendations.

Coordinated the energy management development team to update head impact guidelines for the Daimler Chrysler and wrote the preliminary outline of updated head impact guidelines.

Helped prepare Product Assurance Plan for Head Impact Development in the Scientific Lab Platform of DCX.

Performed 1998 PL NEON European compliance tests (ECE R-17 and ECE R-14) and wrote reports.

Performed 1998 JX FMVSS210/207 development test to evaluate the performance of recliner with change in material.

Ford Motor Company, Project Engineer (Aug 1993 – May 1995)

Contract; Employer DCED, Clawson, MI

Performed Finite Element Analysis using Ford in-house Software V-Crush, Secollapse and Compcollapse.

SPECIAL COMPUTER SKILLS

Microsoft Office, WordPerfect, Harvard Graphics,

PAM-CRASH, LS-DYNA3D, Altair-HyperMesh and HyperView, Algor, (Secollapse, Compcollapse, V-CRUSH) For Linear/Nonlinear Finite Element Analysis

CATIA V5, Unigraphics NX/Teamcenter, SMUG, AutoCAD, CADKEY CAD/CAM Packages

EDUCATION

MS in Mechanical Engineering (1989 - 1992)

University of Windsor, Ontario, Canada

BS in Mechanical Engineering (1984 - 1989)

University of Engineering and Technology Lahore, Pakistan

PUBLICATION

SAE Paper No 970159, “Comparison of Energy Management Materials for Head Impact Protection”.

PROFESSIONAL TRAINING

Designing Plastics Parts and Components

Altair HyperMesh and HyperView for FEA Pre and Post Processing

WERS and GD&T Training at Ford Motor Co

DFMEA, EBOM and GD&T Training at Chrysler Corp.

Contact this candidate