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Project Engineer

Columbus, Ohio, 43221, United States
March 09, 2011

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David Lipka

**** ******** **. ******** ** ***** 614-***-****

Creative Problem Solver Respectful Collaboration with World class


Demonstrated Knowledge of

Plastic Processing Developing Team Leader, Proven Project


Highly motivated, results driven engineering professional with broad knowledge of all phases of product life cycle

from initial concept to production maturation and market usage. Pattern of success developing new solutions to

improve performance, reduce cost and increase marketability for a world renowned OEM in a highly competitive

market. Sought after team member for complex problem solving projects. Demonstrated communication and

presentation skills, honed through constant interaction with engineers, management, suppliers and manufacturing

facilities in a multi lingual environment. Proficient with Microsoft Office (Excel, Powerpoint, Access, Word), MS

Project, AutoCAD, LabVIEW, VBA, MATLAB / Simulink, Mathematica, Minitab, SAP, Lotus Notes

Process Development Strengths


- Design of Experiment Manufacturing Processes (Injection / Blow


- Research and Quality Project Planning Molding, Thermoforming, Printing, Coating,

- Statistical Process Control (SPC) / Validation Assembly)

- Failure Analysis (Microscopy, SEM)

- Test Method / Specification Development


Honda R&D Americas Raymond, OH

Jan 2004 – Present

Material Engineer

Advance design changes as part of a multi disciplinary development team and prepare new ATV and

powersports products for mass production launch with the highest quality and value to the customer.

Research, evaluate, develop and apply new and existing technologies to improve vehicle quality, cost and

performance; Perform testing to evaluate electrical, chassis and frame change points to Honda (HES) and

industry standards (SAE, ANSI, EPA/CARB, ASTM, JIS); Communicate results through formal written

reports and presentations; Maintain detailed documentation and provide support throughout ramp up and

mass production to maintain part / drawing specification; Lead Fault Tree Analysis (FTA), Plan and

Conduct Design of Experiment (DOE), Feed forward c/m into next design or implement running change by

collaboration with domestic and international suppliers and factory quality teams.

• As new model project leader, review and approve drawings, assign and oversee testing, maintain

project schedules, report results to executive evaluators, and standardize development outcome via

internal systems.


David Lipka

• Developed innovative decorative coating for HDPE, more than doubled durability vs previous

material, led prototyping, process development and full vehicle qualification testing; 57% reduction in


• Synergized efforts with other divisions to apply common materials; Cut part cost by 10%.

• Conceived, formulated and prototyped in collaboration with supplier, new high pigment load mold

in color material; reduced raw material usage by 75% with no effect to process or performance.

• Played integral role in the planning, EPA qualification and implementation, including new

equipment investment ($9M), of low permeation fuel tank material; decreased evaporative emissions


• Served as mentor in co op program; trained, directed and coached day to day activities such as

testing by standardized methods and provided motivation and encouragement to pursue of individual


MACtac Stow, OH

Sep 2002 – Aug 2003

Engineering Co Op

Use 6σ methodology and tools to define goals, measure current situation, analyze problems, implement

countermeasures and check/control improvements through completion

Led team through Process Map, Cause and Effect Diagram, Failure Modes and Effects Analysis (FMEA) to

improve quality of adhesive coating production processes; Interfaced with engineers, production

supervisors and contractors to redesign machinery and processes to increase capacity, ergonomics and

process stability.

• Analyzed adhesive coating process, identified and implemented countermeasures; resulting in

50% increase in throughput, realizing $100k annual benefit

• Designed machine components using 2D CAD software


The University of Akron Akron, OH, 2003

B.S. Mechanical Polymer Engineering (BSME / BSMPE), Minor Psychology, Dean’s List

Relevant Coursework:


David Lipka

Thermodynamics Mechanical Design Project

Thermal / Fluid Systems Computer Programming (Fortran, C++, PLC)

Polymer Processing, non-Linear fluids Physiological Psychology

Statics / Dynamics / Strength of Materials Quantitative Methods (Statistics)

Polymer Properties, visco-elastic properties Experimental Design

System Dynamics and Response Cognitive Psychology

Control Systems Design

Intro Electrical Engineering


Basic Japanese Language

EIT Certification Ohio, 2004

American Soc. of Mechanical Engineers (ASME) – Member, Since 2001

Society of Automotive Engineers (SAE) – Member, Since 2004

Society of Polymer Engineers (SPE) – Member, Since 2004

The Adaptive Adventure Sports Coalition (TAASC) Volunteer Instructor, Since 2004

TAASC employs adaptive equipment and techniques to help disabled individuals perform recreational activities


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