Statistical Analysis: Variation, Capability, and Sampling Statistical
Resume:
KEVIN DUNNIGAN
*****.********@*******.***
SUMMARY:
Degreed engineer with over 25 years of experience in Dimensional and Quality Engineering. Experience with design and manufacturing. Knowledge and experience with GD&T, tolerance stack analysis, variation simulation modeling, Gage R&R, root-cause analysis, part, tool, & gage buy-off. Launch experience on numerous vehicle programs. Experience with APQP, FMEA, SPC, PPAP, DOE, Control Plans. Direct interface with body shop for assembly tooling changes during all build phases. Work with stamping to obtain dimensionally stable and quality parts. Ensure Quality Plan is followed and vehicle quality is achieved at manufacturing facility. Integrate with production suppliers. Support prototype build and launch at manufacturing plant until all plant quality and audit issues are solved. Support continuous improvement efforts at manufacturing plant.
SKILLS:
Statistical Analysis: Variation, Capability, and Sampling
Statistical Process Control
Design for Manufacturability
Taguchi Design of Experiments
Die Face Engineering
Sheet Metal Formability
Design for Six Sigma
PFMEA, DFMEA
Project Management
Basic knowledge of Catia V5 and Pro-E
PROFESSIONAL EXPERIENCE:
Magna AIM (contract through Aerotek)
Quality Engineer January 2018 – December 2018
Interfaced with suppliers to ensure product timing, quantity, and quality targets were achieved throughout product development and launch.
Assisted and verified that manufacturing tooling, checking fixture design, build, and GD&T were coordinated.
Ensured APQP process was followed, PPAP was completed, and targets were met per customer requirements.
Analyzed dimensional data and implemented corrective action plans during build events in order to reduce build variation.
Modern Mirror & Glass Co.
Project Manager September 2015 – December 2017
On site manager for commercial projects.
Ensure that necessary parts, tools, staff and equipment are on site for daily build plans.
Direct project planning monitor and control progress in accordance with project timing.
Gestamp NA
Advanced Quality Engineer January 2015 – August 2015
Implemented die and assembly tooling follow-up and buy-off for Tier 1 and Tier 2 suppliers and integrators to ensure quality metrics were achieved per program milestones.
Ensured APQP process was followed, PPAP was completed, and targets were met per program timing as defined by customer.
RLE USA Engineering Services (contract to Magna Interiors and Exteriors)
Lead Dimensional Engineer September 2013 – June 2014
Led dimensional engineering activities for Magna instrument panels.
Developed, led, and managed dimensional datum and assembly strategies that met build objectives and customer satisfaction requirements.
Participated in product engineering and OEM suppliers’ cross-functional teams to resolve dimensional and quality issues.
Coordinated and developed GD&T, measurement strategies, and root cause analysis to achieve dimensional goals.
Analyzed assembly dimensional data and implemented corrective action plans during pilot build in order to reduce build variation.
ATS Applied Tech Services
Dimensional Engineering – Project Management May 2012 – August 2013
Facilitated dimensional engineering efforts with Tesla Automotive Group to root-cause launch phase build and dimensional issues on Tesla Model S electric vehicle.
Reviewed product tolerancing and processing, at detail and assembly levels, in an effort to understand issues and root-cause path related to build issues.
Led activities on assembly plant floor to analyze product assembly, part/tooling fit, interface, and datum coordination. Measured and analyzed critical feature data, recommended corrective actions and next steps in order to achieve quality and dimensional targets.
General Motors LLC
Senior Manufacturing Quality Engineer January 2011 – February 2012
Interfaced with suppliers to ensure product timing, quantity, and quality targets were achieved throughout Vehicle Development Process.
Assisted and verified that dies, manufacturing tooling, checking fixture design, build, and GD&T were coordinated.
Led efforts to ensure quality and dimensional targets were met through all build phases.
CER – CAD Engineering Services
Senior Quality Engineer – Gestamp N.A. January 2010 – December 2010
Supervised die and assembly tooling follow-up and buy-off for Tier 1 and Tier 2 suppliers and integrators to ensure quality metrics were achieved per program milestones.
Verified that APQP process was followed, PPAP was completed, and targets were met per program timing as defined by customer.
Gibbs Technologies, Inc.
Manager, Dimensional Engineering August 2008 – February 2009
Managed dimensional engineering and packaging efforts for all High-Speed Amphibian programs. Programs included:
oCommercial Vehicle – First Responder
oRecreational Vehicle – Aquada (2nd generation)
oPersonal Recreational Vehicle / Watercraft – Quadski
Managed team of dimensional engineers and designers to meet engineering build objectives, packaging constraints, and customer satisfaction requirements on 3 HSA programs, across all vehicle systems and sub-systems (i.e. body, structure, hull, exteriors, interiors, powertrain, and suspension).
Maintained engineering targets that included weight reduction efforts, while still maintaining vehicle quality objectives, simple and repeatable product datum and manufacturing strategies for low volume assembly process.
Kept capital investment and piece part costs to a minimum for initial production product market introduction of all 3 programs.
Managed and resolved dimensional and quality issues, coordinated and developed GD&T, measurement strategies, developed corporate dimensional engineering and quality standards and procedures.
Magna Steyr (formerly Porsche Engineering Services)
Lead Dimensional Engineer / Project Manager November 2004 – August 2008
Lead dimensional engineer for DaimlerChrysler MK49 and MK74 C-Segment vehicles.
Promoted to project manager for DaimlerChrysler MK49 launch at Belvedere Assembly Plant.
Dimensional engineer for Chrysler LC22 structures and exteriors, including launch at Brampton Assembly Plant. Performed Customer Satisfaction Audits on prototype, pilot, and production vehicles.
Managed and maintained efficient engineering manpower during design and launch.
Ensured that all engineering issues were closed following the corporate issue management system (PIECS / e-CIMS). Managed engineering CN’s, using IAA and PER system at launch. Closed all CN’s prior to launch team departure.
Ensured that all Material Cost Management issues (MCM’s) were identified and documented. Made certain customer requirement targets were met or exceeded and budget was maintained.
Developed, led, and managed dimensional datum and assembly strategies that met build objectives and customer satisfaction requirements.
Participated in Product Engineering and OEM supplier cross-functional teams to resolve dimensional and quality issues.
Coordinated and developed GD&T, measurement strategies, and root cause analysis to achieve dimensional goals.
Analyzed assembly dimensional data and implemented corrective action plans during pilot build in order to reduce build variation.
Coordinated, managed, and implemented corrective action plans for engineering and build issues.
QMC LLC
Dimensional Engineering Project Manager August 1998 – November 2004
Developed and managed quality program timing and tasks for customer vehicle development process.
Developed dimensional datum and assembly strategies that ensured stress free builds and conformance to customer requirements.
Participated in Product Engineering and OEM supplier cross-functional teams to resolve dimensional and quality issues.
Coordinated and developed GD&T, measurement strategies, and root cause analysis to achieve dimensional goals.
Analyzed assembly variation and implemented corrective action plans during prototype build through product launch.
General Motors Corporation
Senior Project Engineer August 1994 – August 1998
Developed common corporate vehicle assembly datum strategies for critical characteristics to ensure minimal build variation and stress-free assemblies.
Recommended robust product designs, manufacturing and assembly processes, die line-up, and design alternatives to ensure dimensional and structural integrity with increased process capability.
Performed root cause analysis on body shop fabricating and welding equipment during prototype, pre-production, start-up, and production.
Implemented datum strategies during Vehicle Development Process.
Facilitated cross-functional team meetings with die, product, manufacturing, and dimensional engineering disciplines.
Performed structural and variation analysis of body assemblies using finite element, design optimization, and variation reduction software.
EDUCATION:
Oakland University
Bachelor of Science
Major: Electrical Engineering
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