Engineer Design

JOHN KAPP

***** ********* ***** *****: 734-***-****

Riverview, Michigan 48193

abmbmo@r.postjobfree.com

BACKGROUND SUMMARY

Automotive design and engineering professional with over 15 years relevant experience

in design for manufacture of large, multi-function interior component and systems.

Demonstrated track record in design and problem analysis and solution. Known for

dedication and versatility.

SELECTED ACCOMPLISHMENTS

DESIGN

• Resolved under severe timing constraints for product launch, structural

performance issues of the ‘95 Explorer High Series Console by implementing

changes resulting in increased resonant frequency from 15 to 25 Hz with

production revisions within final evaluation build time frame. Project involved

collaboration with Ford Assembly Operations management, Ford Science Lab,

Design and Manufacturing.

• Spearheaded heating mode airflow effort for 2004 Windstar Semi Center Stack

HVAC systems with insufficient package space, providing design staff with

needed analytical approach. Airflow target exceeded by 13% versus original 18%

shortfall from rapid prototypes to production-tooled parts, avoiding six weeks of

additional development.

• Led design of total ’95 Explorer HVAC auxiliary system. On time Launch

allowed Ford to lead No American compact SUV segment with rear seat A/C for

nearly three model Years.

• Generated production concept & design for soft center AC duct that utilized

unique linear vibration joining process. Five week development allowed Ø6

Zephyr Climate system to overcome a dB noise deficit to target for 1st

production vehicle.

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• PROJECT ENGINEERING

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• Championed a $16 Material Cost reduction for 2002 Ranger by benchmarking

segment cockpits and convincing chief engineer to implement $3 enabling my

own company to realize their shared target.

•

• Completed sample submission of J97 Meter Hood to Mazda in Thailand,

gathering all data in a foreign language environment (Hiroshima) salvaging an

American gage deemed unusable by local contractors. Customer accepted

package after I repatriated to Dearborn.

•

• Appointed Project Engineer six month after graduation, leading field evaluation

and production implementation of 8’ rubber tired asphalt paver units, releasing all

manufacturing drawing for that model including three engines.

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• Page Two

• JOHN KAPP

• CAREER HISTORY

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• FORD MOTOR COMPANY Dearborn, MI

2007 to 2008

Senior Product Engineer

P415 Door Trim. AIMs and build resolution for same from Verification Proto

through

Tool Tryout in three assembly facilities.

•

• COLLINS AND AIKMAN, Dearborn, MI

2002 to 2006 Tier one supplier of automotive interior systems.

Senior Product Engineer

• Concept to production of 2006 Lincoln Zephyr Instrument panel ducts and

appliqués.

• Launch support Ø3 Aviator cockpit including warranty and cost reduction. Design

support ____and project leadership for instrument panel capacity foam in place

tooling.

VISTEON AUTOMOTIVE SYSTEMS, Plymouth, MI

1990-2002

Tier one supplier of climate, fuel, cockpit, exterior and chassis systems.

Product Design Engineer 2001-2002

Design, performance targets, packaging, vendor Ø4 Windstar Front HVAC module.

Truck V.C. Resident Engineer 1998-2000

Liaisoned operating units to customer chief engineer on carry over and freshened

programs including launch lead, cost reduction funding approvals and quality

management.

Product Design Engineer 1994-1997

Final Launch of Explorer Console. Current model engineer on Explorer instrument

Panel. Represented company for nine months in Japan as liaison engineer.

Product Design Engineer 1991-1993

Design of Explorer HVAC auxiliary concept to production. Current model air

handling engineer Ford Truck systems.

WOODBRIDGE / INOAC, (Now division of Johnson Controls), Troy, MI

1988-1990

Tier one supplier of seating and instrument panels.

Project Engineer

Supported launches, implemented cost reductions, lead manufacturing and customer

support for Ford dedicated Ranger/Explorer instrument panels.

VARIOUS DESIGN AND ENGINEERING POSITIONS

1978-1988

EDUCATION /TRAINING

BSME, University of Iowa, Iowa City, IA SAE Member

Additional education and training:

• Autodesk AutoCAD 2009 Certified •

Customer Focused Teams 1999 Facilitation Skills, FPDS Sourcing 1998

PMT Targets, FPDS Overview, Benchmarking 1997 GD&T, APQP, FMEA design for FIP.

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