Engineer Project
Resume:
RICHARD M. THODEN
Plymouth, Indiana 46563
***********@*****.***
http://www.linkedin.com/in/richthoden3
SUMMARY
Proven engineer with broad experience base in product design, application, and manufacturing, from concept
through production. Skilled in drawing development, prototypes, testing, mechanical design, and control
systems. Dynamic systems and process thinker. Electro-mechanically adept. Strong interpersonal skills at all
levels. Project management approach. Hands-on aptitude. Analytical and detail oriented. ISO 9000
experience.
TECHNICAL SKILLS
Microsoft Office (Excel, Word, PowerPoint) 5S
Microsoft Project Kaizen Teian (KZT)
SAP Continuous Improvement Process (CIP)
Statistical Analysis Failure Mode & Effects Analysis (FMEA)
Blueprint / Drawing Development Prototype / Production Control Plans (PCP)
ASME Y14.5 Design Verification Plan & Report (DVP&R)
Geometric Dimensioning & Tolerancing (GD&T) Production Validation Plan & Report (PVP&R)
Computer Aided Design (CAD) Design Review by Failure Mode (DRBFM)
Product Development System Optimization
EXPERIENCE
Robert Bosch LLC, South Bend IN 1997–Dec. 2009
Senior Engineer, Disc Brakes, 1999 - 2009
Design, development, and production release of disc brake assemblies for automotive applications.
Responsibilities include: Prints and technical documents, prototypes, testing, cost reduction, data analysis and
reports, issue resolution, technical communications, project management, and project team participation through
the product development life cycle, as well as core product design development.
• Design release responsible for 3 products from concept initiation to production
• Member of corporate driven strategic customer brake business development team
• Released new silicon rubber dust boot for high temperature application
• Defined caliper face dimensional envelope for customer snap on cover plate
• Led engineering of 4 product lines for 3 engineers on cast iron component supplier replacement team
• Improved customer brake pedal apply feel with 30% housing, 5% hydraulic stiffness increase
• Resolved existing clip to housing interference issue along with tooling change for stiffness increase
• Identified statistically significant root cause factors via correlation and statistical analysis of empirical data
• Benchmarked 12 competitive products
• Developed design guidelines detailing physics, design rules, and standard prints for product development
• Interfaced with CAD personnel to develop drawings utilizing GD&T and ASME Y14.5
• Performed dimensional stack ups for form, fit, function, packaging, safety, and manufacturability
• Produced test plans, analyzed test data, judged conformance to acceptance criteria, issued test reports
• Identified and reduced probability of high risk failure modes with plans developed utilizing DFMEA’s
• Met project timing utilizing project management techniques to generate work plans, establish timing targets,
and set priorities for print release, prototype deliveries, and verification / validation testing
• Regularly communicated with customers, suppliers, and project management team of casting, machining,
manufacturing, assembly, quality, purchasing, marketing, sales, and program management personnel
• Actively communicated with laboratory support teams to monitor test progress and establish due dates
• Extensive experience with casting, machining and assembly operations
RICHARD M. THODEN, III
Senior Engineer, Vacuum Boosters, 1997-1999
Joint venture for application of Japanese supplier design for North American Manufacture. Responsibilities
include: Project management and processing of prints, cost reduction implementation, and project team
communications.
• Managed different print release requirements for 8 customers and 15 programs
• Utilized Microsoft Project to set task priorities, manage resources, generate print release work plans and
schedule project start dates for 50% of the released prints in a 150 man engineering organization
• Achieved 100% on-time delivery drawing release performance
• Improved print release cycle time and quality by creating one page check list of common print errors
• Improved timeline work effort estimate accuracy via drawing size effort prediction model
• Directed work efforts of 2 designers and 2 clerks
• Reduced costs with supplier plant visits in support of sourcing to North American Supply Base
US Granules Corporation, Plymouth IN 1995-
1997
Project Management Engineer, Aluminum Recovery Processing and Granulation
Technical oversight of new plant and process for recovery of aluminum from laminated foil scrap.
Responsibilities include: Technical interface to plant design supplier project engineers and installation
coordinator, plant build and equipment installation progress and issue resolution, conveyor design.
• Calculated conveyor material handling design attributes (material flow and paddle size)
• Attained on time conveyor system delivery via design definition, fabrication sourcing, and status monitoring
• Used Auto Cad for drawings of conveyor geometrical and dimensional lay out
• Analyzed viability of process waste heat use for electrical power generation and cost reduction
• Resolved plant construction and equipment installation issues and details
Allied-Signal Corporation, South Bend IN 1984–1995
Development of Anti-Lock Brake (ABS), Traction Control (TCS), and Electric Power Assisted Steering (EPAS)
Systems for Passenger Car, Light, 4x4, and Medium Duty Truck Applications
Engineering Supervisor, Senior Engineer, 1993-1995
Responsible for operational oversight and logistical support of Minnesota and Alaska Winter Test Facilities,
vehicle testing and development of ABS function and performance control algorithms, supervision of test facility
supervisor, development engineers, and vehicle test technicians for medium truck, passenger car, and globally
harmonized ABS / TCS.
• Planned and Implemented $110,000 budget for facility capital project improvements
• Represented company on SAE Cold Weather Testing Roundtable discussion
• Tuned, optimized, and released performance algorithms and parameters for 3 production ABS programs
• Enhanced customer confidence in control system function via face to face technical discussion
• Reduced unwanted ABS rough road initiation utilizing creative Proportional-Derivative Control
• Created, refined, orchestrated, and led product demonstration routines for professional sport venues
• Performed DOE to understand large variance in stopping performance on ice surfaces
Senior Engineer, Engineer, Associate Engineer ABS and TCS, 1984-1985, 1986-1993
Responsible for advanced development and vehicle testing of ABS and TCS control, function, and performance
algorithms on 4x4, SUV, Light and Medium Duty Trucks, production release, tuning and testing for first 4x4 ABS
application.
• Developed system and control functions via microprocessor software changes and vehicle level evaluations
inclusive of function, performance, and fail safe
• Pioneered successful, leading edge development of ABS on low cost, 3 valve system for 4x4 applications
with worse case suspension, drive train and center of gravity vehicle configurations
• Obtained satisfactory balance of stability and stopping performance on split mu with deceleration feedback
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RICHARD M. THODEN
• Eliminated 4x4, ice ABS drive train chatter with situation detection and response based algorithm
• Improved deceleration smoothness with pressure cycle frequency faster than suspended mass response
• Advocated benefits of TCS on medium duty truck applications
• Developed test protocol specification requirements and acceptance criteria
• Created vehicle performance test plans, reduced test data, drew conclusions
• Improved engineering and test driver efficiency with 1 page test plan and protocol sheet
• Utilized instrumentation and computer aided data recorders to analyze real time data
• Verified / validated stopping performance for production release of 4x4 vehicle application
• Verified failure mode conformance to Federal Motor Vehicle Safety Standards / Regulations
• Planned, organized, and led first company adventure into winter testing
• Hot and cold weather vehicle level product evaluation testing, planning, logistical support and reports
Engineer, Electric Power Assisted Steering, 1985-1986
Development of a wheat stone bridge, steering column torque sensor and wiring. Responsibilities include:
prototype preparation, durability testing, fixture design, and manufacturing communication.
• Saved $30,000 combining 4 discrete lock to lock rotation variations into one torque fatigue test fixture
• Created and utilized FORTRAN program for 4 bar mechanism test fixture design
• Performed fatigue testing and failure analysis of torque sensor assembly
EDUCATION
B.S., Mechanical Engineering
Purdue University, West Lafayette IN
PROFESSIONAL DEVELOPMENT
Cause & Affects Analysis ISO 9000 / QS9000
Design of Experiments (DOE) ISO 14000
FMEA and Special Characteristics ISO / TS 16949
Surface Texture Specification Change Management
Fastener System Technology Business Ethics
Advanced Product Quality Planning (APQP) Product Liability
Production Part Approval Process (PPAP)
Statistics for Engineers: Normal curve theory, process capability, sampling theory, significance testing,
statistical process control (SPC), X Bar and R Charts, Histograms, Pareto Charts, and Fishbone Diagrams.
PRODUCT KNOWLEDGE
System Process Component Materials
Hydraulic Castings Springs Cast Iron
Pneumatic Machining Bushings Corrosion / Protective Coatings
Electro-mechanical Assembly Clips HSLA Steel
Control Fine Blanking Castings Stainless Steel
Electronic Stamping Housings Rubber
Injection Molding Steel Plates Phenolic Plastic
Bleed Screws
Pistons
Seals
Protective Boots
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