Engineer Engineering

JOHN MAILLEY

Dear Human Resources Manager:

My name is John Mailley and I am currently seeking consideration for the position of

Mechanical Engineer – Chassis, Drivetrain, and Hydraulic. I have extensive experience

leading large diverse product development teams, ensuring all deliverables are met, and

measuring milestones along the way. I led my core CFT consisting of product,

manufacturing, quality, and sales, throughout product life from concept to production

launch while maintaining a cohesive environment. I was also the lead customer contact on

all of my programs, and worked within my customer’s PDT to develop and implement any

changes needed to insure the design met their performance objectives. During this time I

became an expert at managing the delicate balance between customer requirements and

demands, versus my own company's best interests. My programs run well, launch on time,

and maintain good margins.

Previously, for six years I worked at General Motors Truck Engineering in the

preproduction vehicle build department. My vehicle level knowledge is vast, having worked

on every area of the vehicle and vehicle system there is. During this time, I had the

opportunity to work on all platforms in the prototype stages. I functioned in many different

capacities from Technical Writer to Liaison Engineer; on platforms as small as S-Truck, to as

large as Medium Duty. I also worked directly in all phases of the business: scheduling,

manpower, material handling, root cause analysis, specifications, BOMs, testing

requirements, and process engineering. With me, comes a tremendous understanding of

current product engineering and manufacturing technologies as well as the ability it takes to

get any job done.

I have a long history of inspiring customer confidence and satisfaction and I bring with

me a wealth of experience that is difficult to match. Some of my areas of training include:

APQP, DFMEA, PFMEA, DVP&R, 5 Phase, 5S, 5 Whys, 8D, Reliability & Confidence,

DOE, VA/VE, CAD/Catia V5, QS9000, TS16949, PPAP. Please review the enclosed

resume for further details on my extensive background and qualifications, and feel free to

contact me as I look forward to discussing how my skills could benefit your company.

Sincerely,

John Mailley

3120 WIRELINE • CARO, MI • 48723

PHONE: 989-***-**** • E-MAIL: *********@***.***

JOHN MAILLEY

OBJECTIVE

To secure a position that allows me to utilize my strong engineering

background, program management experience, and problem solving skills.

PROFESSIONAL EXPERIENCE

05/2000 - 04/2009 Dura Automotive Systems Inc. Rochester Hills, MI

Senior Systems Engineer/Product Engineer

n Product Engineering: Assigned to Driver Controls Division, responsible for

complex safety critical electromechanical assemblies and components

(electronic throttle controls and adjustable pedals). Created and

implemented new designs and released design changes for current

products. Met with vendors to review new products and purchased part

status. Reviewed designs for manufacturability and assembly. Led

DFMEA and PFMEA creation. Worked through and resolved all

design, integration, and envelope packaging issues with customer

throughout development. Directed FEA efforts and interpreted results.

Conducted part tolerance stack-ups and specified GD&T on products.

Designed and built prototypes. Experience with stamped, molded, and

cast products. Participated in peer reviews and documented best

practices. Periodically worked at customer locations as Design Release

Engineer/Integrated Supplier. Provided innovative solutions to complex

problems. Provided root cause analysis and corrective actions for all

customer issues on released products. Performed competitive

benchmarking.

n Design: Created designs in Catia V5. Provided direction to design staff

for all changes and product modeling updates. Reviewed and approved

all drawings and parts lists for release.

n Program Management: Responsible for all program management activities

and risks. Provided single point contact from initial request for estimate,

to product launch. Led cross functional team (CFT) consisting of

product, quality, manufacturing, and sales. Established and maintained

program timing, assuring all key dates and milestones/deliverables were

met. Led quote reviews and tracked design vs. budget. Created and gave

technical presentations. Facilitated brainstorming sessions. Responsible

for all VA/VE and MCM initiatives. Trained customers in product use

and service procedures. Led Stage-Gate process. Quoted new programs.

Led CAR and 8D investigations.

n Testing: Originated and maintained ADV/DVP&R. Wrote all test

requests, approved test set-up, wrote test validation reports, and analyzed

test failure modes. Organized and implemented all necessary corrective

actions. Provided proving grounds and customer test site support.

n Customers: Fostered trustful and beneficial relationships with customers:

Chrysler, Delphi, Ford, General Motors, General Motors Truck Group,

Honda, John Deere, Porsche, SsangYong, Toyota, and Yorozu.

n Authoring: Created new test specifications for critical items previously

never captured:

GM World Wide Engineering Standard GMW14551, ETC Pedal Lab Durability

Test. Original issue detector and creator of test standard for electrical variation of

electronic throttle control pedal at idle. Now know as: “Appendix G: Within Ignition

Cycle Evaluation At Environmental Extremes.”

3120 WIRELINE • CARO, MI • 48723

PHONE: 989-***-**** • E-MAIL: *********@***.***

GM World Wide Engineering Standard GMW14551, ETC Pedal Lab Durability

Test. Original issue detector and creator of test standard for throttle apply force

smoothness. Now known as: “Appendix F: Apply Force Consistency Evaluation.”

GM North American Standards GMN5196, Clutch Pedal Mechanism Lab

Durability Test. Wrote entire original test specification; previously customer had no

component level test requirement.

04/1994 - 04/2000 General Motors Truck Engineering Pontiac, MI

Engineering Floor Liaison

n Last assigned to Medium Duty truck platform. Heavily involved in

process engineering of program, tooling setup, assembly line sequencing,

and assembly documentation.

n Worked for one and a half years as Liaison Engineer on P model chassis.

Completely responsible for resolution of all design issues found during

prototype build stages from Mule through Pilot.

n Worked for one year as Liaison Engineer on S/T Truck, and M/L Van.

Completely responsible for resolution of all design issues found during

prototype build stages from Mule through Pilot.

n Assigned for one year as Special Project Coordinator for mid-size truck

platform, working closely with Build Managers, Specifications group, and

prototype build floor to assure integrity of builds.

n Assigned to Lead Build Team for one year, providing technical support

to all Truck Group platforms. Lead build team was responsible for

reviewing vehicle bill of material vs. specification/RPO and driving quick

resolution to any conflicts.

n Resolved product engineering conflicts by working directly with

prototype build floor to correct any design concerns early in process on

C/K platform.

n Worked as technical writer on GMT 600 (G-van) program providing

documentation on build problems and creating lessons

learned/procedures for future programs to follow.

EDUCATION

Macomb College Warren, MI

Associate of Applied Science, Automotive Technology

n Graduated Magna Cum Laude

n Also Associate of General Studies, Magna Cum Laude

n 105 College Credit Hours with a 3.69 GPA in all course work

ACCREDITATIONS

Certified Master Mechanic

REFERENCES

References available upon request.

3120 WIRELINE • CARO, MI • 48723

PHONE: 989-***-**** • E-MAIL: *********@***.***

Contact this candidate