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Manufacturing / Process Engineer Ford Motor Company

Sterling Heights, MI
March 31, 2018

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Ford Sterling Axle Plant Eric M. Condron Home Address

***** ***** **** *-****: 5335 Old Cove Rd.

Sterling Heights, MI 48310 Cell: 248-***-**** Clarkston, MI 48346



Education: Oakland Community College, Auburn Hills, MI.

Clarkston High School – Graduated 1991

Experience: Ford Motor Company (Axle Driveline – Power Train Operations), Sterling Heights, MI.

2012-Present (Manufacturing Engineer) – Dept. 29 and 40

Real time monitoring – using FIS to track first time through issues or specific machine faults.

Developed extensive machine specifications and runoff procedures to improve Overall Equipment Effectiveness at Launch.

Maintain Dynamic Control Plan (Dept. evidence book) and develop process check sheets to ensure compliance with Ford specifications.

Trouble shoot PNC and CMM, Fanuc based machine systems.

Support production and assist with training departmental employees.

Order machine components through the Ford CPARS system.

Conduct machine Runoffs, Capability and Gage R&R's.

Assisting skill trades to trouble shoot down machines.

Ford Motor Company (Axle Driveline – PTO), Sterling Heights, MI.

2007 - 2012 (Gear Analyst) – Dept. 5 (Including Dept. 1, 14, 29, 40, and 42)

Ensuring a working level of knowledge and skills to all departmental employees.

Responsible for launch of all cutting, lapping and gear checking machines.

Conducted Machine Runoffs, Gage R&R's, and assisted w/ DCP, and FTT Improvement Plans.

Maintained and controlled all gear departments and supported axle assembly lines.

Analyze axle warranty returns to the plant and inspect gear quality.

Controller of all blade grinding, cutting and lapping summaries from past to present for all gear


Studied and implemented recycled 320 grit lapping compound resulting in a 40% cost reduction.

Visteon Automotive Systems (Axle Driveline - Chassis Systems), Sterling Heights, MI.

2002 – 2007 (8.8” Premium Gear Upgrade Gear Analyst) – Dept. 29

Assisted with Runoff and Launch of the 8.8" Phase II Premium Gear Upgrade Cell (Dry Cutting / Lapping).

Assisted with the development and installation of the lapper Closed Loop Compound System to improve

gear noise and quality concerns.

Utilized PNC - CMM Equipment through various studies and SPC charting.

Implemented SPC and SFT charting for the department to use and maintain for departmental gear quality.

Assisted with development and implementation of lapper nick detection and correlation to EFT and vehicle sensitivity levels.

Studied and implemented lapping compound change from 220 to 280 grit improving gear tooth Ra by 30%.

Visteon Automotive Systems (Axle Driveline - Chassis Systems), Sterling Heights, MI.

2001 – 2002 (8.8” Premium Gear Upgrade Gear Analyst) - Dept. 14 (including Dept. 1, 4 and 5)

Assisted with runoff and launch of the 8.8" Phase I Premium Gear Upgrade Cell (dry cutting / lapping).

Improved axle gear noise internally and externally for new program launches.

Gained extensive knowledge and experience in gear manufacturing processes.

Responsible for daily gear analysis and quality (gear tooth contact, noise, etc.) for all gear families.

Gained extensive training and experience in Technical Gear Analysis from Gleason Works, Rochester, N.Y.

Visteon Automotive Systems (Axle Driveline - Chassis Systems), Sterling Heights, MI.

2000 – 2001 (7.5" / 8.8" Tool / Gear Analyst) - Dept. 1, 4 and 5

Study tool life from machine cutting summaries to improve cutter tool life.

Face Mill / Face Hob cutter blade coating studies to increase tool life.

Able to set up, trouble shoot and run 17A testers, single flanks, PNC inspection, blade grinding,

cutter build, arbor assembly, cutting and lapping machines so that others can learn from me.

Ford Motor Company (Axle Driveline - Chassis Systems), Sterling Heights, MI.

1998 - 2000 (Gear Lab / Gear Development)

Set up 9” Ford Racing Gears - development and production.

Assist in redeveloping existing gears and develop new gears to the plant.

Machine set up and tear down, arbor replacement and cutter preparation.

Ford Motor Company (Axle Driveline - PTO), Sterling Heights, MI.

July 1997 Axle Tubes Manufacturing

Certifications Green Belt Certified (2008)

Lean Manufacturing / Value Stream Mapping (2001)

Technical Software: Minitab, Microsoft Office Suite.

Skills Programming: Klingelnberg PNC: Gear tooth quality analysis, Gleason Hypoid Gear Cutters and Lappers,

Oerlikon Lappers, Gleason and Oerlikon Single Flank Testers

Technical Gleason Gear Process Theory, (Rochester, N.Y.).

Training Oerlikon Technical Gear Engineering Level Training: Face Hobbing, Lapping, and SFT Analysis.

Previous Lyon Gear and Machine, Inc., Rochester, Mi. (Dec. 1996 – July 1997)

Employer Gear Machine Operator

Military: Air Force

May 1992-November 1996

Basic Training at Lackland AFB, TX

Military Police Technical School at Fort Dix, NJ

Stationed at Offutt AFB, Ne. 1992 – 1996

Securing: The E-4B Alt. Air Force One (The National Airborne Operations Center for the president, secretary of defense and Joint Chiefs of Staff). The RC-135 (provides near real-time on-scene intelligence collection, analysis and dissemination capabilities). The Command Center (Alternate Pentagon), Elite Guard.

References Bryan Harrison

Cell: 586-***-****

Randy Bahnmiller

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

John Bonner

Cell: 248-***-****

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