Engineer Design
Resume:
Donald Edward Lemke
**** ***** **., ***********, ******** 48734
abluqb@r.postjobfree.com
Mechanical engineering professional with 31 years of interdisciplinary automotive/medical product design and
manufacturing engineering experience seeking senior design engineering position. Primary experience in mechanical design,
manufacturing, and packaging of electronics for harsh and interior environment applications. Led cross functional teams in
technical management role from concept development and design though to launch of cost effective, volume & content
scalable systems. Skilled in product design & optimization, virtual prototyping, and problem solving. Experienced in
commonly used CAD / CAE SW.
Delphi Automotive Systems (formerly named: Delco Electronics Corp., AC Spark Plug Div.
Employment GMC)
Lead Mechanical Design Engineer – Automotive Displays 2006 Present
Lead Mechanical Design Engineer for MY2011 Automotive Forward Collision Warning System Head
Up Display for a European OEM
• Lead technical support and interface to customer
• Negotiation of cosmetic A surface with OEM Design Studio for customer approval
• Successful packaging for all HUD components in exceptional tight spatial constraints
• Managed 2 CAD Designers to meet deadlines
• Tolerance stack ups, DFMEA
Lead Mechanical Analysis Engineer for MY2012 Automotive Instrument Cluster for a major Japanese
OEM
• Set up dozens of FE Analyses on snaps, plastic springs, knobs, mounts, connectors, PCB assemblies,
etc.
• Created 7 DRBFMs for design changes to this Japanese OEM’s previous supplier’s instrument cluster
• Performed hand calculations in support of the DRBFMs
• Developed snap, mounting feature, trip reset stem, stepper motor Building Block Documents for
Delphi’s Displays product line
Stepper Motor Engineer for Automotive Instrument Clusters
• Launched 2 new stepper motors for automotive instrument clusters
• Instrumental in supplier selection and supplier technical management
• Tolerance stack ups, DFMEA, DFMEA, DOE
Lead Mechanical Design Engineer – Medical Wheelchair Electronics 2003 – 2006
Led a team of 3 mechanical engineers in the design of powered wheelchair electronics (9 modules)
•
Developed and designed Dual 100 Amp Motor Controller for Wheelchairs
•
Performed thermal calculations for the thermal path and heat sink
•
Extensive design and release experience of assemblies and systems utilizing die cast, stamped,
•
injection molded, and machined components for harsh environment use.
Designed waterproof enclosures (IP 56 cast aluminum & plastic)
•
Developed and documented design project proposals including cost and performance targets.
•
Managed critical path tasks and developed backup plans for items of potential risk.
•
Engineering Group Manager – Occupant Detection Systems 1999 2002
Donald E Lemke August 10, 2010 1
Implemented a new design center; staffed 7 engineers, and set up the design lab
•
Managed mechanical and systems engineering teams in Michigan and Indiana
•
Developed mechanical design procedure for developing the bladder sensor for Occupant Detection
•
System
Approved all bladder sensor designs worldwide (NA, Europe, and Asia)
•
Worked closely with customers on requirements documentation, critical issues, and risk management
•
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Donald E Lemke August 10, 2010 3
Mechanical Systems Engineer – Electric Power Steering Controller 1996 1999
Documented the mechanical requirements for EPS controllers
•
Coordinated controller integration into steering column
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Developed motor to controller interconnect design
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Extensive knowledge of sealants and conformal coating used for harsh environment products.
•
Developed a concept for a sealed EPS integrated rack, motor, and controller using the rack as the heat
•
sink
Worked closely with systems and electrical engineers to develop power duty cycle for design and
•
testing purposes
Provided customer support during implementation and testing
•
1979 1996
Other Positions
Stepper Motor Development Engineer
•
Designed and developed stepper motors for automotive instrumentation
Analyzed the magnetic circuit concepts with Maxwell FEA software
Thick film power resistor design and manufacturing processes Engineering Supervisor
•
Designed a 6σ resistor terminal reducing scrap by 99% and early warranty failures by
70%
Manufacturing Engineer – Coil winding and stepper motor assembly
•
Developed the fist robotic coil winding machine for the division
Implemented equipment to wind 7 million coils
Rensselaer Polytechnic Institute, Troy,
Education 1994
NY
Masters of Science, Engineering Science
University of Detroit, Detroit, MI 1979
Bachelors of Science, Mechanical Engineering
Defensive Publication: Printed Circuit Coil Mechanism
•
Publications Defensive Publication: Servo Gauge Mechanism
•
Defensive Publication: Inductive Encoder – Phase Encoded
•
Society of Automotive Engineers Paper #830327 “Gagesite – Computerized
•
Vision for Automotive Instrument Calibration”
Donald E Lemke August 10, 2010 4
Creation of DFMEA’s Knowledge of Power Electronic
• •
Relevant Experience Circuits
Creation of Dimensional Stack Ups
•
Knowledge of Screen Printing
Creation of DRBFM’s •
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Knowledge of Various PCB
Design of Aluminum Die Cast •
•
Materials
Components
Knowledge of Various Plastic
Design of Aluminum Stampings •
•
Materials; ABS, PC/ABS, PP, PC,
Design of Bolted Joints
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PBT, POM
Design of Connectors
•
Lead Cross Functional Team
Design of Electronic Assemblies in •
•
Lead FEA Analysis
High Vibration Environment •
Support of Customer Meetings
Design of Head Up Displays •
•
Support of Quotations
Design of Instrument Clusters •
•
Knowledge of PCB De Paneling
Design of LED Lighting •
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Techniques
Design of Light Pipes
•
Knowledge of PCB Processing
Design of Medical Products •
•
Techniques; Single Sided Reflow,
Design of Plastic Injected Molded
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Double Sided Reflow, Selective, and
Components
Wave
Design of Sealed Electronic
•
Knowledge of Plastic Ultrasonic
Products •
Welding
Design of Stepper Motors
•
Member of Corporate ME Peer
•
Design of Thick Film Hybrid
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Review Board
Components
Member of Corporate ME Steering
•
Experience with Microsoft Office;
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Team
Excel and Word
Experience with AutoCAD
•
Experience with Foreign
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Manufacturing Locations; Mexico,
China, Portugal, Singapore,
Thailand, Switzerland
Experience with GD&T
•
Experience with GM, Ford,
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Chrysler, Toyota, Volvo, Daimler,
VW
Experience with Maxwell magnetic
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analysis software
Experience with Microsoft Project
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Experience with Microsoft Visio
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Experience with MiniTab Statistical
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Analysis Program
Experience with Plastic Graining
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Experience with Six Sigma Design
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Experience with Solidedge CAD
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Experience with Solidworks CAD
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Experience with Team Center
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Experience with Thermal Interface
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Materials
Experience with Tier 1 Integrators
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Donald E Lemke August 10, 2010 6
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