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GEORGE SANDA - M.Sc. U.S.A. Citizen

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

Street, Lincoln Park, MI 48146

Tel :313-***-****

E-mail: acfovx@r.postjobfree.com

EDUCATION:

**** *** ******** **** ***** Works 9.0: Hyper Mesh, Motion View,

Radios Linear + Impact

1982 POLYTECHNIC INSTITUTE, FACULTY OF MACHINE BUILDING TECHNOLOGY,

Bucharest, Romania

MASTER OF SCIENCE, MECHANICAL ENGINEER (recognized with

a Master's Degree in

the USA, Canada and the Netherlands). Major Field of

study: PRODUCT DEVELOPMENT

HISTORY OF WORK AND DUTIES:

DESIGN REL. ENGINEER GM -Gonzalez 29401 Stephenson Highway, Madison

Heights, MI 48701 Jan 2010-Present time

Responsibilities: Design 3D Model /Package/Integrate/Validate/Production

Launch of Body, Closures & Trim Exterior Parts & Asy.: Front fascia,

Grille, GOR, Pillar Appliqu, Glass (Seals, Regulators,

Controls)/Encapsulated Glass, Pillar Reveal Molding, Body Side Closures,

LED Lighting, Wheel Liner, Closeouts Panel, films, badging, injection

molded parts, Body Side Otr., Roof.

Analyze of DES Preliminary Section & submit preliminary data to Studio.

Take Studio Surface and develop Trim Exterior Solids, interfacing Body Side

Outer, Front & Rear Body. Interface with DTS - Dim. Technical Spec group to

establish Gaps & Flush condition. Write DCS (Design Concept Sheet), e-SOR

(Statement of Requirement), e-WO (Work Orders) to process the following

info: define a design concept, materials, Color Gloss & Grain, Part and

Tooling Cost associated with and obtain Management approval for it. Make

design changes recommended by Compartment Integration Team. Collaborate

with the following Teams and matter Experts: DTS, Validation/ Testing,

Studio, Manufacturing, Pre-Process Operation, Supplier,

Material/Color/Gloss/Grain Engineers, Compartment Integration Team,

Critical Interference Team, CAE/Stampability/Mold Flow, Program Eng. Mngr,

Change Management Leader, Engineering Group Mngr, Vehicle System Engineer,

Body Integrators, Eng. Operation Mngr, Vehicle Architecture Mngr,

Specification Analysts, Service Eng., Buyer, Supplier, Surface Product

Eng., Studio and Component Planning Analyst, Product Planning, Program

Management Team, & Core Integration Team. Write, adjust and update

DFMEA/PFMEA, DFSS, GD&T, DVA, DVP&R, EPQP & PPAP info.

To speed up the communication process, I write & read in German, Spanish,

and Italian.

Plastic Automotive Materials (must be in harmony): ABS, ASA, TPO, PC,

PP/EPDM +Talc; Tolerances of finished surfaces;

+/-0.2 to +/-0.5; Main Features: Draft Angle, Die Pull Angle/Die Pull

Direction (avoiding Die Lock), Graining Surface (on walls

min 3deg angle to die pull direction); Press Tonnage estimation: 1500mm

for 2000tone press or 4-5Tons/square in.

Mold Materials: Steel 38-45 HRC (Hard Rockwell) for Production parts.

Mold Materials for Prototypes: Aluminum

(7075 & 2024 Hard make max 100,000 parts), Mild steel, Epoxy. Mold

aesthetic detriments placed all in hidden area: Parting Lines, Ejector

Pin Marks, warping/twisting, Sink marks, burrs (excess material in thin

area), gate marks (from runners). Doghouse for

attachment Clip is created with slide Perpendicular to Die Draw. Over-

molding are previously molded parts reinserted to allow a second layer

(like rubber) to cover the first part. Two shot injection molding:

Sequential injection & forming of two compatible materials like:

Santoprene TPV (Synthetic Rubber) bond with PP (Poly-Propylene) or Poly-

Ethylene bond with TPO.

Hartzel Aerospace/GE. Belcan 10200 Anderson Way, Cincinnati, OH 45242

Jan 2009-Jan2010

Aircraft acoustic, elastomeric, composite & Al Structure Engineer. Design &

Develop/ Package/Prototype/Test/Production Launch/Dimensional Management

(3D, 2D, GD&T, EBOM, Catia V5)/FEA analyze: Jet Engine Auxiliary Power

Unit, Exhaust / Intake & Nacelle. Design & Package Instrument Panel Gages

wiring and electric/electronic systems EESE & Wire Harness.

PRODUCT ENGINEER - Mitsui Kinzoku, 40000 Grand River, Suite 500, Novi,

MI. Jan. 2005- Dec 2008

37702 Enterprise

Court Farmington Hills, MI 48331

Responsibilities: Design 3D/2D /Package/Integrate/Test/ Validate

/Production Launch of Body Trim Components.

Design using Catia, 3D parametric complex Solids - instantly modifiable

solids, generating, in a timely fashion, many iterations of the product in

development. Analyze FEA Stress analysis (with Catia &Nastran for windows)

to optimize the structure.

Design parts & tooling (Catia 5/ 4, UG-NX4-5) /prototype/ engineering,

package: BIW closures, Door Modules, Seals, Hardware (latches with sensor &

switch, handles, key locks, hinges, ext mirror, window mechanism) Sun/Moon

Roof, Lighting.

Handle aspects of: Purchase/Sale/ Material Cost/Project/Program

Management, customer/ supplier interaction, quoting/negotiations,

product development/presentation, SPC (Ppk, Cpk), SOP, PSO, Tooling Buy

off, Production Material Required Date. Apply processes: Plastic

Injection/Rotary/Blow/Compression Molding, Thermo - Foaming and (Chrome

or Electro) Plating /Painting, &

ultrasonic/ vibration/ hot plate plastic welding.

Design & Package EESE. NVH testing, benchmarking & target setting;

analyze Transfer Path & propose design solutions.

Process VSA Dimensional Management Data: Arithmetic Mean/ Median,

Frequency Distribution, Variance, Standard Deviation,

RSS = Root sum of Squares.

Apply Robust Design (Taguchi Method) to reduce development Time and Cost

and improve fundamental function of product/process.

Use Parameter Diagram (P-Diagram) of Product/Process to identify

Signal/Input and Response/Output associated with the design concept and

identify noise factors and control their settings so that the deviation

from the ideal curve is minimum and at a low cost.

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Major accomplishments:

a. Family of 20 Side Door Latches: Play a key role in development of a

production/ testing technical data.

b. Family of 14 Hood Latches: Proliferate form 2 to 14 type of latches with

enhanced electronic features.

PRODUCT ENGINEER - Daimler Chrysler - TEC (Technical Engineering

Consultants, Inc.) June 1998-Dec.2004

1153 Oak Valley Drive, Suite 1, Ann Arbor, MI 48108.

Responsibilities: - BIW Trim Design 3D & 2D / Package/ Validate /

Production Launch/ Tooling design/FEA /Project & Program

Management following up packaging issues until they are completely

solved. Evaluate prototype, manufacturing process

& redesign for improvement Support launch activities; develop GD&T

and tolerance stack up:

* On the design level, during the development process (taking into

account stock up tol.)

* After receiving information from endurance testing facilities and

from test laboratory.

- Design (Catia 5 or 4), test, validate, and assist suppliers for

Trim Interior: Console, Seats, Carpet, Door, body side,

roof, cargo, shelf, pillar garnish, IP/ instrument panel/cockpit

area, carpet, soft Trim, restraints, wiring, connectors.

- Approve PPAP - supplier production parts prior to shipping production

volumes. Design FMEA, Test Planning DVP&R.

- Define and Plan APQP (Advance Product Quality Planning). Design,

develop and validate the product and process.

Take action on DFMEA to reduce or eliminate the effects of the

potential root cause of a failure.

- Design/Develop/Integrate/Dimensional

Management/Prototype/Test/Production launch of

- Design / develop / prototype / test / production launch of BIW and

Bumpers, Fascia, Body Sill, Lighting (Fog/Tail/Head-Lamp),

ext. mirrors, wipers, grilles (GOR-Grille Opening Reinforcement),

handles, key locks, latches, hinges, window mechanism,

front fascia, grille, GOR, bolster, functional trim, underbody

shields, wheel arch liners, front end module (FEM),

active

grille shutter,badges, decklid / liftgate appliqu s, decklid /

liftgate lower finish panels, running boards, box top

moldings.

Design / develop / prototype / test / production launch of

Instrument Panel interfacing the BIW and all the

front/behind components:

Connectors, ECU, Fuses, Cooling/Heating Lines, Cigarette Lighter,

Media/Radio, All Meters and Glove Compartment.

Apply processes such as: cold forming tooling/ closed die forming/cut &

sew of covered parts/ Sewing, wrapping& patterning.

Follow up Quality issue using Deign For Six Sigma 6?).

- Provide assistance until production stage. Manage program timing,

budget and EBOM. Evaluate prototype; confer with other

departments and redesign for improvement. Identify cost saving

opportunities. Interface with other teams to ensure

quality targets.

-NVH testing, benchmarking & target setting. Noise/NVH of

BIW/Chassis/Engine measure/ranking and set a target.

-Identify vehicle level Root-cause NVH issues, analyze Transfer Path &

propose design solutions

-Preliminary Design/Packaging of Chassis parts and assemblies: Cooling,

HVAC, Fuel, Exhaust Systems, Suspensions.

Major accomplishment:

Play a key role in development (cradle to production) of Jeep Wrangler,

Liberty, Grand Cherokee.

DESIGN ENGINEER - Porsche - SR1, 13122 LaSalle, Huntington Woods, MI 48070

Sept.1997-June 1998

Duties: benchmarking, Designing, Dimensional Management, Testing,

Validation, Production Launch and Body Trim.

Design/prototype/test/Production Launch Trim Interior: Seating, Restraint

(Seat Belt, Head Rest, Airbag), Carpet,, Airbag,, Interior lighting,

Mirror components, trim-pillars, Instrument Panel/Cluster/ Cockpit, Wire

Harness, restraints, pillar-trim, seating, scuffs & head liners, consoles,

door trim, Seals, Cowl & panel quarter trim, Latches, Handles, key locks,

Hinges. Use processes as Aluminum casting / extrusion. Design and FEA test

BIW structures for Structural Impact, Cracks and Fractures. Develop 3D

models and 2D drawings including GD&T and tolerance stack up for specified

performance. Use of materials: carpet, plastics, fiber, cut & saw textile.

Coordinate with supplier for source tooling, material and purchased

components to implement the design.

Recognize and evaluate the potential failure modes of a product and the

effects FMEA. Maintain EBOM.

Identify action that could eliminate or reduce the chance of the potential

Failure Mode from occurring by determining the root cause. Design a

verification plan DVP&R. Identify vehicle level Root-cause NVH issues,

analyze Transfer Path & propose solutions.

AVE preliminary Design/Packaging Chassis components: Suspension,

Steering, ABS Brakes, Cooling, HVAC.

Major accomplishment:

Play a key role in development/design (cradle to production) of ULSAB

-Ultra Light Steel Automotive Body; improve test results in

crashworthiness torsion 80%, bending 52%, body mode 58% combining

materials and processes: 90% high/ultra high strength

steel, hydro forming- injection of high pressure fluid into a mould to

shape a steel tube (roof rails), tailor welding (different

grades and thickness of steel welded in a single blank for stamping).

Develop quality procedures & implement controls; Metrology &

Measurement of statistical VSA analysis (Ppk/ Cpk, ? -Mean,

? = Standard Deviation, SK - Skewness, KU - Kurtosis, Normal/Non-

Norman Distribution, uncertainty measurement), GRR -

Gauge Repeatability & Reproducibility. Quality System: interpret/apply

regulations & standards for products/ processes.

Compare statistical Data: Actual, Simulated with Monte Carlo (random

Manufacturing Process), versus Estimated one based

on VSA Curve. Perform RSS-Root Sum Square of Tolerance/Variance.

CATIA DESIGN ENGINEER-ARADCO MNGMT LTD

March 1996-Sept.1997

452 Charles Street, Windsor, Canada, N8X 3Z1 Duties using CATIA &

CIMLINC:

Construct and modify Chrysler 3D models (brackets, hinges, shields,

fenders, plastics) and assemblies; design 2D drawings from 3D models;

checking fixtures, Dies and body car parts, according to Chrysler GD&T

standards, receiving Chrysler models in CATIA mailbox, sending them back

for validation or to the vendors through IGES files, writing Sample Parts

Inspection Reports.

Design/ Dimensional Management of production launch for BIW parts: front

and rear structures and underbody, confer with other design staff

evaluating prototype parts and redesign for improvement. Manage technical

documents for multiple projects and maintain

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and develop Document Database and Bill of Materials (BOM). Design for Lean

Manufacturing (lower production cost, higher profit, superior quality and

greater flexibility). Apply processes: cold forming tooling/ closed die

forming.

ASSESSS / EVALUATE Process Capability, if PROCESSS is STABLE, Capability

Process Index Cpk.

Demand Quality system to have well defined / established / implemented:

1. Quality Syst. with Management Responsibility & Contract Review with

PURCHASING.

2. Design, Document/Data, Tier 2 Supplier product & Process,

Measuring/Test Equipment

-Approve PPAP - supplier production parts prior to shipping production

volumes. Design FMEA, Test Planning DVP&R.

PRODUCT DEVELOPER - CENTURY LTD., 275 Stephenson, Montreal, Canada

1993 Sep - 1996March

Duties, using CATIA & CIMLINC-3D:

1. Design/engineering /CMM check Dies and Fixtures / test BIW: underbody,

fender, body side inner, dash/cowl panels.

2. Evaluate prototypes and redesign for improvement. Manage program timing,

budget, quality, production launch issues.

-Coordinate with supplier tooling sourced, material. Purchased components

to implement the design, Maintained EBOM.

-Recognized and evaluated the potential failure modes of a product & the

effects FMEA. Manufacturing technologies.

PRODUCT ENGINEER - CONTROLEC ENGINEERING BV.

Aug 1990 - 1993Sep

De Brauweg 20, Rotterdam, the Netherlands.

Duties using Catia and F.E.A.: Design/prototype/test: BIW upper structures

(hood, roof), and fender front/rear, body side inner, Doors/Door modules

and underbody. Apply processes: cold forming tooling/ closed die forming.

Design / test: Instrument Cluster, consoles, pillar-trim, restraints, door

trim. Design / prototype/test: Trim Ext.: fascia, bumpers, lamps, body

sill, wipers, glass, equipment & Wire Harness electronic sys. EESE. Apply

GD&T; stack up tolerance, Design FMEA, Test Planning DVP&R.

-Performed engineering analysis. Evaluated and verified design proposal.

Support design reviews and meetings.

- Manufacturing plan and assist to support program/business objectives.

Implement quality within AS9100/ISO9001.

PRODUCT ENGINEER - PROJECT LEADER. ROAD, SEA, AIR TRANSPORT INSTITUTE,

1982Sep - 1990July

Dinicu Golescu 38, Bucharest, Romania.

Duties: Design using Catia, perform stock up tolerances, calculate

structural (FEA) integrity, test, validate and assist

manufacturing at supplier side for automotive parts.

Design/Prototype/Test/Production Launch BIW: front and rear structures,

Underbody (rails, cross members, front and rear floor pan), roof and

hood.

Design/Prototype/Test/Production Launch Trim Interior: headliners, cowl

and quarter panel trim, pillar rim, carpet,

restraints, scuffs and Instrument Cluster,. Trim Ext.: fascia, bumpers,

appliqu, lamps, grilles, wipers, and wheel liners.

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