Engineer Design

Steven Henry Dunham

**** *** **** ****

Union, MO 63084

Phone:

Cell 504-***-****

E-mail:

******************@*****.***

Professional experience Summary

**/****-**/****

Henniges Automotive

New Haven, MO

Senior Engineer, Finishing SBU

. Maintained weatherstrip manufacturing operations/equipment to

provide optimum capability

. Provided ideas and drove continuous improvement projects

. Supported the development of new projects

09/2011-11/2012

Nissan Motor Company-North America

Smyrna, TN

Forward Model Paint Engineering

. Developed throughput model for Service parts E-coat system.

. Launched new Infinity JX through paint and sealing system.

. Launched new Pathfinder front and rear plastic molded fascias.

02/2007-05/2010

Lockheed Martin Corporation

New Orleans, LA

Design Engineer Senior, Orion Program

Thermal Protection System/Heatshield Design Lead.

. Develop and maintain drawing tree for Orion CM heatshield structure.

. Release drawings for GTA heatshield structure.

. Interface with NASA ADP during model development.

. Worked with development team to input designs and review structural

outputs utilizing FEA analysis.

09/1986 - 06/2006

Ford Motor Company

Dearborn, MI / Louisville, KY

06/04-06/06

Production & Material Handling Supervisor, Kentucky Truck Stamping

Facility. Louisville, KY

. Supervise production operation of stamping press, including personnel

& shipment of parts to suppliers.

. Supervise approximately 50 person UAW departments on rotating schedule

of 3 shift plant.

07/99-06/04

Product Development Design Engineer, Body Engineering, Body structures

Sheet metal design, Super Duty Plant Vehicle Team, Kentucky Truck Plant.

Louisville, KY

. Improve current production sheet metal designs for continuing

product/process improvements and/or cost savings and quality

improvements and warranty cost reductions.

11/91-07/99

Product Development Design Engineer, Body Engineering and Advanced Vehicle

Technology, Static Sealing Design.

Dearborn, MI

. Design and develop new static sealing concepts and designs and

implement them on new vehicle models.

. Release pump applied or die cut installed, heat activated chemical

sealers. Static sealers include body shop applied weld through

expandable pump applied and die cut sealers, structural adhesives for

body joints and paintable sealers applied over exposed body joints.

. Develop sheet metal joints to accept sealers.

. Develop designs to meet all cost, quality, appearance and processing

requirements.

09/86-11/91

Division Process/Manufacturing Liaison Engineer, Sealing Systems.

Dearborn, MI

. Develop and launch new sealing processes in assembly plants during new

model vehicle launches.

. Optimize and revise current model sealing design processes.

. Primary responsibilities included sealing the entire vehicle from

water leaks, wind noise and air leakage.

. Verify and maintain sheet metal joint sealing processes in body and

paint shops, glass installation and sealing, door and door window

weather strip installation process and sealing.

. Liaise with vehicle development and design engineers.

. Test vehicles, both current and prototype, for leaks to verify sealing

capability.

Summary of qualifications

Six Sigma Black Belt Certified

Green Belt Certified

Extensive knowledge of CAD (Pro-E, AutoCAD, Solid Works) SPC, QOS, ISO

9001, Experimental design, FMEA, DVP&R, Lean Manufacturing Processes

Education

1981-1986

University of MO-Rolla Rolla, MO

Bachelor of Science-Chemical Engineering

Detailed Employment History

2013-Current Henniges Automotive New Haven, MO

Senior Engineer Weatherstrip Manufacturing Facility

Oversaw operations of various Weatherstrip manufacturing machines,

including pin insertion machines, molds, cut to length processes, coating

robot, among others.

Developed continuous improvement projects to increase productivity and

reduce scrap

Developed error proofing plans to increase quality of parts shipped to

customer.

Program manager for the launch of several new programs.

Developed tooling and capital cost breakdowns for new equipment or for

refurbishing existing tools.

Maintained timing plans and schedules.

2011-2012 Nissan Motor Company-Smyrna, TN

Forward Model Paint Engineer

Developed throughput model for Service parts E-coat system. The model was

used to launch the Leaf battery case into assembly line production.

Launched new Infinity JX through paint and sealing system. Developed

processing methods for painting and sealing the vehicle through manual and

automated systems through the paint system.

Launched new Pathfinder front and rear plastic molded fascias. Developed

and refined masking process. Developed 4 part aluminum casting paint buck

method to transport molded fascias through the paint system.

2007-2010 Lockheed Martin Corporation

Design Engineering Lead, Heatshield Structure, Orion Program

Design titanium heatshield structure models for Orion Space Capsule.

Develop drawings for release to Manufacturing. Develop and maintain

drawing tree for design. Maintain cost and weight schedules for model

designs. Interface with structural and stress engineers to develop optimum

structure design. Interface with NASA Development Engineers to maintain

requirements and specifications to the program. Interface with Test

Engineers to develop testing criteria to meet program requirements.

Interface with suppliers to develop manufacturing process for the

heatshield.

1986-2006 Ford Motor Company

Production and Material Handling Supervisor, Kentucky Truck Stamping Plant

Supervise production operation of Schuler Press including personnel and

shipment of stamped parts to suppliers. This includes manning and

maintaining operation while controlling cost and quality. Supervised

approximately 50 person department on rotating schedule of three shift

plant. This included press operation, manual racking of stamped parts and

PMHV loading of racks into trucks and rail cars for delivery to customers.

Product Development Design Engineer, Body Sheet Metal Design,

Super Duty Plant Vehicle Team,

Kentucky Truck Plant

Improve current sheet metal designs for continuing product/process

improvements and/or cost savings and quality improvements and warranty cost

reductions. Provided Kentucky Truck Assembly Plant sheet metal design

changes for Super Duty trucks and Excursion SUV's. Changes included form

and shaped improvements on stamped metal, punched or extruded hole changes,

welding changes among others. Developed changes in CAD, analyzed

structural changes or improvements using FEA tools, provided cost and

timing estimates and followed the change through implementation in the

assembly plant.

Product Development Design Engineer, Body Engineering & Advanced Vehicle

Technology, Static Sealing Design

Design and develop new static sealing concepts and designs and implement

them on new vehicle models. Release pump applied or die cut installed,

heat activated chemical sealers. Static sealers include body shop applied

weld through expandable pump applied and die cuts and structural adhesives

for body joints and paintable sealers applied over exposed body joints.

Develop sheet metal joints to accept required sealers. Designs met all

cost, quality, appearance and processing requirements. Participate in and

led static sealing team in all prototype builds and vehicle launches

(assembly processes and testing). Verified designs and provided design

changes when necessary.

Provided design support and core expertise for static sealing designs for

currently produced vehicles.

Develop and maintain generic core design standards, best practices and

specifications for static sealing platform.

Major programs-- 1993 Windstar pre-program design and launch in Oakville,

ON, Canada; Lincoln LS pre-program design, 1999 Thunderbird pre-program

design.

Division Process Liaison Engineer, Sealing Systems, Body & Assembly

Operations

Develop and launch new sealing processes in assembly plants during new

model vehicle launches. Optimize and revise current model sealing design

processes. Primary responsibilities included sealing the entire vehicle

from water leaks, wind noise and air leakage. Major tasks were verifying

and maintaining sheet metal joint sealing process in the Body shop and

paint shop (both manual and robotic applications); glass installation

processes and sealing; door and door window weather strip installation

process and sealing. Liaison with vehicle development and design

engineering to develop sealing processes for new vehicles launches. Test

vehicles, both current and prototype, for water leaks, wind noise and air

leakage to verify sealing capability and/or adequacy of design/process

changes.

Develop new testing methods for continuous improvement.

Optimize and revise current model sealing design processes.

Major programs--1987 Thunderbird Launch in Lorain, OH; 1990 Explorer Launch

in Louisville, KY; Lincoln Mark VIII pre-program development in Dearborn

and Wixom, MI.

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