Engineer Design
Resume:
Dennis Mallari
Milford, MI 48380
*********@*******.***
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Objective: To obtain a position that would enable me to implement my skills and
experience to secure a challenging career in the engineering field
Experience:
Dec 09 - present Navistar Inc., Fort Wayne, IN
Lead Interior Trim Engineer
• Define problem assumptions, boundary conditions, and design
requirements for medium to heavy duty truck interior components
• Mentor and lead lower classification engineers and designers in design
guidance, project documentation, adherence to established drawing and
performance standards
• Participate in and lead project and design reviews
• Coordinate as appropriate with suppliers, purchasing, manufacturing,
and other engineering personnel to develop the information required to
complete assigned engineering projects
• Use the appropriate quality tools including design requirement
documents and design guidelines in developing designs
• Responsible for the project design integrity including supporting the
project through production launch
• Responsible for developing plans for all work within assigned project
scope and leading the project to completion within the agreed estimates
Apr 02 – Dec 08 Johnson Controls Inc., Plymouth, MI
Product Development Engineer
• Handled all product feasibility, design and technical interfacing with the
customer, suppliers and internally from concept through production
launch for under the hood, interior and exterior trim plastic components
for Ford, GM and Toyota vehicle programs
• Prepare and maintain DFMEA, DVP&R, FEA, APQP/PPAP, GD&T
and tolerance stacks
• Provide BOM and technical information in support of cost estimating
and other activities
• Provide technical direction to CAD designers, manufacturing/process
engineers, suppliers, sales, purchasing, analysis and test engineers, and
tooling
• Experienced in plastic injection molding process, plastic part design,
mold design and properties of various plastic materials
• Interact with program management team to resolve issues and keep
programs on time
Jan 00 – Apr 02 Continental Plastics, Fraser, MI
Design Release Engineer
• Develop, validate and release interior trim plastic component designs
from concept through production launch for GM vehicle programs
• Engineering liaison with the customer, suppliers and internal
• Implement product design according to the Component Design
Standards
• Review and approve detailed component drawings and schematics
utilizing GD&T, DFM and tolerance stacks
• Participate in cost reduction, benchmarking and vehicle applications
• Support design reviews to prevent unnecessary cost in the initial releases
Feb 97 – Jan 00 US Farathane Corporation, Sterling Heights, MI
Program Manager / Product Development Engineer
• Coordinate design, analytical activities and cost estimates to result in
beneficial under the hood and exterior trim plastic design concepts and
alternatives from concept through production launch for Ford and GM
vehicle programs
• Interface with required cross functional disciplines and departments for
program support
• Conduct all phase and gate reviews
• Manage the product program proactively to ensure timing, costs, and
objectives are met for all customer milestones
• Generate design validation documentation to help ensure sound design,
such as DFMEA, DVP&R, etc..
• Identify and record any issues relating to the product, process, tooling
and quality system
Jan 95 – Feb 97 Toledo Molding & Die, Toledo, OH
Facility Engineer
• Provide technical support on maintenance issues, problem diagnosis and
resolution
• Ability to analyze problems and implement improvements with process
engineers on existing plant equipment designs (plastic injection
molding)
• Enforced lean manufacturing improvements (5S, Kaizen, Six Sigma)
and cost reduction plans
• Ensure that all environmental procedures and guidelines are met
• Implemented total preventative maintenance program (CMMS) to all
facilities
• Complete cost projections by analyzing investment, return and savings
• Administer modifications and repairs to facilities/equipment with proper
approvals, bid documents, contracts, cost estimating and inspections
• Update job knowledge by participating in trade shows and educational
opportunities
Sep 86 – Jan 95 United Parcel Service, Livonia, MI
Industrial Engineer / Plant Engineer Supervisor
• Improved work systems by studying facility layout, work flow and work
methods
• Utilization of facilities and equipment to improve overall efficiency of
plant operations
• Conduct time and motion studies
• Recommend methods for improving worker efficiency and capital
equipment utilization
• Establish work measurement programs and analyze work samples to
develop standards
• Develop and maintain all total preventative maintenance programs
• Project management including planning, estimating and executing
• Improvement, retrofit, and redesign of facilities, system and equipment
• Regulatory compliance with a wide variety of governmental laws and
standards
• Purchase of requisite tools, equipment, parts and materials
• Monitor equipment modifications and installations by maintenance
personnel and outside vendors
Education:
Sep 82 – Sep 86 Lawrence Technological University, Southfield, MI
Bachelor of Science in Mechanical Engineering
• Minor: Manufacturing
Technical Skills:
• DMU (digital mock up – Catia V5)
• Vis Mock Up / Vis View
• AutoCad
• Unigraphics
• Proficient in Ford WERS
References:
• References are available upon request
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