Engineer Design

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Objective:

To obtain a challenging growth oriented career opportunity where I could

utilize my experience and education.

Experience:

General Motors Corporation - Warren - Michigan

LEAD ENGINEER (Jan07 - April09)

. Global Lead for Control display buttons, Power Mirror Adjust Switch /

Module, Door Latch Release & Touch Pad Switch to develop strategy for

commodity re-use, writing component technical specifications, setting

forth component functional design direction. Implemented mistake /

error proofing, zero defect and best practice standards to achieve

cost and warranty reduction.

. Chaired Value Add / Value Engineering workshops to achieve cost

reduction ideas and targets.

. Created and developed initial concepts per specifications that

optimizes the ergonomics and aesthetic design needs.

. Responsibilities included component & sub-assemblies design &

packaging of Electro-Mechanical Switches for automotive interior, with

consideration of touch/feel/effort/illumination, mechanical mechanism

and manufacturing process such as injection molding, insert molding,

die casting, laser itching and vacuum forming.

. Proven ability to manage design-related projects and activities with

minimal direction or supervision and experience working with or

managing external design resources.

. Led programs / projects from initial supplier sourcing, design

reviews, GD&T, tolerance stack-up, prototype / production tooling

release, EMC / product validation testing, PSO and PPAP.

. Team leader for prototype / production builds for mirror switches,

control panels and touch pad switches. Monitored day-to-day build

activities and responded to all assembly and functional issues for

resolution.

. Interfaced and coordinated with suppliers, prototype / production

tooling and manufacturing facilities to resolve issues using problem

solving methods (Six Sigma), SPC, root cause analysis and corrective

action including 8D.

. Experience working directly with both domestic and overseas vendors.

. Knowledge of LIN Bus communication and messaging to / from module /

switches.

BorgWarner Emission / Thermal Systems - Auburn Hills - Michigan

PROJECT ENGINEER (Jun05 - Dec06)

. Responsible for design and release of Pneumatic Diesel EGR Valve for

automobile per customer's engineering specifications and packaging

requirements.

. Lead responsibility for components and sub-assemblies drawings release

for prototype and production tooling, GD&T, gages & fixtures, DFMEA,

validation testing and provided launch support to assembly plant in

China.

. Chaired design review meetings with product development team for CFD,

finite element analysis, design robustness, design for manufacturing

and assembly.

NSK Steering System America Inc. - Ann Arbor - Michigan

DESIGN ENGINEER (Oct03 - Dec04)

. Responsible for design and release of Electric Tilt and Telescope

(ERR) Steering Column for automobile per customer's engineering

specification, FMVSS and vehicle packaging requirements.

. Chaired design review meetings with cross functional engineering team

for natural frequency, finite element analysis, packaging, crash

analysis, DFMEA, DVP&R and interference / clearance studies with

Steering Column mathdata.

. Design Release responsibility for I-shaft, Lock Housing and Flexible

Coupling.

Teleflex Automotive - Troy - Michigan

PRODUCT ENGINEER (Sep01 - Apr03)

. Designed & Developed ETC (Electronic Throttle Control / APPS

(Accelerator Pedal Position Sensors) with accelerator pedal pad

assembly from initial design concept, vehicle packaging, mechanism

design, finite element analysis, design validation testing, DFMEA,

FMVSS and finally PPAP as per customer's engineering specifications,

functional performance and transfer function input/output

requirements.

. Interfaced and coordinated with customer, supplier, prototype &

production tooling facility, assembly facility and supported APQP

meetings for root cause analysis, GD&T, gages & fixtures to resolve

open issues and thus meeting project time-line.

. Developed Engineering Specifications for Angle and Position Sensors.

DaimlerChrysler - Auburn Hills - Michigan (On Contract)

RELEASE ENGINEER (Sep99 - Mar01)

. Responsible for release of power sliding door switch, heated seat

switch, hazard switch, wipe/intermittent wipe & wash switch for rear

wind-shield for minivan platform, keeping in view electrical system,

functional performance, manufacturing and assembly requirements per

DaimlerChrysler Engineering Specifications.

. Supported and coordinated activities with suppliers relating tooling,

validation testing and resolution of open issues to develop Electro-

Mechanical Switches as required by electrical component group and

hence achieved build objectives for minivan platform.

. Provided launch support at Windsor and St. Louis Assembly Plants for

vehicle programs to respond to any potential assembly issue for

electrical switches.

Kostal of America Inc.- Farmington Hills - Michigan

PROJECT DESIGN ENGINEER (Jun96 - Sep99)

. Responsible for design & development of automotive Multifunction

Switch with functions such as wipe, intermittent wipe, wash & wipe,

turn-signal and cruise control per customer's specifications from

initial concept to customer's approval, prototype / production

tooling, validation testing and finally PPAP meeting project time-

line.

. Designed Key Buzzer Switch and high current Ignition Switch for

GMT250/360 steering column programs.

. Conducted cost competitive benchmarking for multifunction switch.

Lucas Industries Inc. - Troy - Michigan

DESIGN ENGINEER (Jul90 - Jun96)

. Responsibilities included component & sub-assemblies design and in-

vehicle packaging for Electro-Mechanical Switches for automotive

interior usage, with consideration of mechanical mechanism and

manufacturing process such as injection molding, insert molding, die

casting, laser itching and vacuum forming.

Education:

MS, Engineering Management, New Jersey Institute of Technology,

BS, Mechanical Engineering, NED University of Engineering & Technology,

Other Relevant Skills:

CATIA, AutoCAD, GD&T, E-Square, Design Robustness, SPC, PSO, APQP, DVP&R,

DFMEA, Microsoft Project, Microsoft Word, Microsoft Windows, Excel, Power

Point, Lotus Notes.

Travel and Relocation:

Open to travel and relocation as required.

References: Available upon request.

Status: U.S Citizen

Phone: 248-***-****

Email: ***********@*****.***

ZULQARNAIN KHAN

28978 Forest Hill Drive,

Farmington Hills, MI 48331

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