Engineer Design

Gregory E Gac

**** ****** *****

Troy, MI, *****

Home 248-***-****

Cell 248-***-****

****@************.***

SUMMARY

A Senior Product Engineer with extensive production launch experience in Automotive Interiors specializing

in soft skin and acoustics. A strong design and development background forged with a diverse career

featuring “hands on” experience spanning the creative process from concept illustration to post launch

program management. Able to communicate knowledgeably with the design and tooling communities.

Deliver multiple projects on time with a strong eye on customer service and satisfaction.

PROFESSIONAL EXPERIENCE

March 2009-Present

Populus Group Contracted to Navistar Defense,

Fort Wayne, IN

LEAD PROJECT ENGINEER, CAB SHEET METAL / INTERIOR

Design Release, Change Control and Production Launch of five configurations of 7400 series Severe Service

6X6 trucks for military applications .

• Duties include on site plant support of prototype and production builds.

• Scheduling and coordination of FMVSS and International ITBR FEA and full vehicle testing.

• Design release utilizing Team Center /Unigraphics NX4 Software

• Creation of supplier quote packages including part drawings, material specifications, and weld

requirements for outsourced assemblies extrusions and break formed parts

July 2007- July 2008

EASi Engineering Contracted to General Motors Performance Car,

Warren, MI

LEAD ENGINEER

Design release and SOR for the GMX627 Rear Compartment Trim and Acoustics.

Conducted weekly PDT meetings and design reviews. with all interfacing body, closures and bumper

systems groups

Continuous engineering on current production KAPPA product line as well as administration of Customer

Service for EASi Engineering as on site representative for bundled engineering service team.

Delivered 100% on time design release of 627 compartment trim.

Delivered 100% of production pull ahead parts within job 1 time frame.

Innovated the design of 3 additional acoustic counter measure .parts post launch, Bringing two additional

suppliers on board and creating new tooling in a manner that still met all IVER build evaluation timing.

Administrated CTO work orders to reduce multiple fastener usage reducing cost and complexity

September 2003- February 2007

Lear Corporation,

Auburn Hills, MI

SENIOR PRODUCT ENGINEER

Interfaced with customer to coordinate key Interface of Design, prototype and production design, DFMEA &

DVP&R in accordance with design for Six Sigma. Managed suppliers and tooling for: under hood acoustic,

trunk trim, package tray carpet assemblies.

Delivered all assigned components on VDP timeline schedule providing full PPAP on or before program

delivery date

Introduced quilted aluminum tunnel silencer and acoustic tunnel insulator to the Cadillac and Buick

programs delivering 225.000 / 87,500 units of additional sales beyond original awarded content.

Provided customer plant support on all component families managing supplier issues and mid cycle

enhancements

Optimized acoustic insulator usage on the Cadillac and Buick trunk trim eliminating 3 part numbers and

providing a lower cost product that still exceeded customer targets.

October 2002- September 2003

Clarion Technologies,

South Haven, MI

PROGRAM MANAGER/ LEAD ENGINEER,

Nissan WZW/ZW/UL Plastic Seat Trim

Administration of post production release design changes between the design source and the Tier Two

customer. Coordinated change releases to tool sources; coordinated prototype and production tool build and

delivery; production PPAP of over 200 injection tools and assemblies including: Production run at rate and

DV testing, Customer support as on site production source representation

Administrated a very difficult program transition between an incumbent and a new Tier Two supplier

occurring between production tooling launch and tool delivery. Negotiated design changes, prototype runs

and graining.

Directed all plastic part design change utilizing personal design insight and the expertise of production

launch team.

January 2000- October 2002

Textron Automotive Company / Collins & Aikman,

Troy, MI

SENIOR PRODUCT ENGINEER

Component design oversight, DFMEA, Project timing and plant/customer support through PPAP of all Tier

One: Injection, Cast Skin, Vac Form and Closed Mold Injection Foam tooling.

Tier two purchased components included:

Structural steel & Aluminum clad trim

Wood Rapped

Articulated Storage

Leather

HVAC

Electrical Content

On two world class luxury door trim panel programs

Innovated new best practice for foam fill around tight corners, introducing arteries and ridge brakes to hard

edges allowing faster foam fill, reduced cycle time and reduced scrap rate.

Facilitated full team DFMEA preparation meetings resulting in a program template that was adopted

throughout the business unit.

April 1997- January 2000

TAC Automotive Contracted to DCX Jeep Truck,

Detroit, MI

RELEASE ENGINEER

Design release and project timing of carpet soft trim, Jump Seat and acoustic components on the 1997-2001

Dakota & Durango. Coordination of interior interfaces and changes with hard trim and sheet metal,

Evaluation of supplier CAD data utilizing CATIA, Coordination of N.V.H. integration activities between

program designate testing facility and individual sealing and interior trim component suppliers. On call

production plant support for all production issues regarding assigned UPC codes in Sheet Metal, Paint Shop

and Trim Chassis Final

Innovation of new product and material usage resulting in

US Patent no. 6106045 for cabin pressure exhauster trim (1999 Dakota Standard Cab)

US Patent no. 6116677 for Extended Cab exhauster housing/acoustic panel / child tether storage. (2000

Dakota Extended Cab)

October 1995- April 1997

Global Technologies Contracted General Motors MID/LUX,

Warren, MI

SENIOR PRODUCT DESIGNER DOOR SHEET METAL, CGS

Wire frame and surface design of sheet metal door systems. Coordination of door swing and deflection

criteria with weather seal. interior trim and all interfacing commodities. Formulation of studies for design

modification, and technical data management.

EDUCATION and TRAINING

Bachelors of Science - Mechanical Engineering

Lawrence Technological University, Southfield MI

2 Year Certificate, Diesel Heavy Equipment

Penn Foster, Scranton PA

Design for Six Sigma Certified

SAE Member

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