Engineer Design

June ****

Gary D. Johnson

**** ********* **, *******, ** 28025

Cell Phone 252-***-**** Email: **************@***.*** OBJECTIVE

To work as a Senior Design Engineer, optimizing team talent, software and resources in a cutting edge 3D design and analysis environment, part of a team which manufactures a cost effective and high quality product. QUALIFICATIONS

Lead others with a natural teamwork approach, while maintaining individual opinions and creativity.

Use and encourage a hands-on, practical engineering approach, emphasizing results.

Proposed, designed, tested and implemented cost reduction projects which totaled over $500,000 in annualized savings for several companies.

Have logged 17,000+ hands-on hours on Windchill/ PDM Link, Pro-E and Creo, coached and managed co-workers on solid and surfacing modeling techniques, modeled complex castings, plastic injection molded, sheet metal, and various styled tractor exterior and interior parts.

Coached teammates on using Design for Assembly and Value Engineering techniques, considering cost drivers, tolerancing, fixturing, tooling and practical issues early in the design process.

Use Ansys workbench for strength analysis.

EDUCATION

B. S. DEGREE - Agricultural Engineering, May 1984

Machine design emphasis Iowa State University

WORK EXPERIENCE

Senior Design Engineer April 2010 – Dec 2015

Entegee (Engineering Services) Dubuque, Iowa

Work for Doosan Portable Power, Statesville, NC May 2015-Dec 2015: Primary duties include processing engineering change notices, drawing changes and design work, with emphasis on meticulous checking of documents. Windchill / PDM Link used to process change notices, including task coordination and communication. Suggested and implemented cost reduction and fit-up problem resolution on sheet steel enclosure parts for 1 series of portable air compressors.

Work for NACCO Materials Handling Group (NMHG), Greenville, NC April 2013- May 2015: Populated components in new functionally grouped ProE top assembly models for new aerial man lift product. Covered many Engineering and design tasks including components packaging, basic harness routing, hydraulics routing, controls and features placement. Plastic, plate, and sheet steel parts design work. Linkages and mechanism design work. ProE geometry live reviews for groups of people, viewing full top model. Work for John Deere Turf Care, Fuquay-Varina, NC January 2011- April 2013: Large Zero Turn and Front Mower - Commercial mowers update program including Tier-4 emissions, styling and features improvements. Concentrated on cost reduction and practical feature improvements to steering column structure and controls, RH console with multiple controls, frame structural changes and operator platform & seating options. Pushed the comfort zone of existing design, assembly and parts fabrication paradigms, with several significant changes used. Used large model techniques in this ProE working environment with intense packaging issues communicated between vehicle group, and subsystem specialists.

Work for John Deere Dubuque Works, Dubuque, Iowa April 2010- December 2010: Assisted High Speed Dozer group with faceted styling work. Implemented various forestry cab changes. Majority of time spent organizing “top model” and components of conceptual cab, to be used on both log skidders and feller-buncher machines. Design issues revolved around implementing a near-full rotating seat with controls suited to combinations of forward and/or rearward usage. Ended work during concept stage.

Senior Design Engineer March 2004- July 2009

AGCO CORP, Jackson Operations, Jackson MN

Coached contract workers and co-workers related to development of chassis/frames linkages, drawbar, integrated fuel tank and related for new Challenger MT900B, the highest horsepower articulated tractor in production in the world, at time of introduction. Resolved frame quality problems considering complex fixturing and geometric dimensioning and tolerancing with manufacturers in India. Worked with systems team members for problem resolution, cost reductions and new feature introductions several years past initial production. Developed chassis/frame modifications to package Caterpillar Tier 4 after treatment module; coordinated frames development with engine, hydraulics, electrical and power train teams’ members. Program canceled due to over running engine supplier development costs.

June 2016

Introduced MT900B team to ProE large assembly management methods. Managed communication of full tractor 3D geometry inside and outside of AGCO, to toy manufacturers, suppliers and 3rd party implements (attaching to tractor).

Resolved track alignment problems by implementing vertical position controls to idler wheel support structures. Improved reliability of track systems and 3pt hitch. Invented track tensioning system using air springs to replace high pressure hydraulics, for cost reduction and increased reliability, with patent granted.

DESIGN ENGINEER September 1995- March 2004

John Deere Product Engineering Center, Waterloo, Iowa Sept 1995 – Sept1998: Pro-E part and assembly modeling, drawings, kinematics, fit-up and functional analysis; PDM database management and release procedures. Suggest design and engineering improvements with emphasis on cost reduction. Assisted the 9000 tractor group, which resolved problems related to heat and vibration effects on SMC components. Resolved tolerance and fit-up, assembly and quality issues on molded plastic, rubber and steel components. Also worked with cab group; modeled injection molded command arm housing on Pro-E with improvements for use with new seat. Assisted the 8.1-liter engine group with cost reduction issues and quality problem resolution. Used VSA software with Pro-E for GD&T for correct tolerancing application, and complex 3-D variation analysis.

September 1998 – May 2002: Continued work for 9000T group on 3 pt. hitch and wide swing drawbar including related damped motion issues. Worked with marine engine and natural gas engine teams on cost reduced alternator mounting system for 10.5/12.5 liter marine engines, heat exchanger and related accessories for new 8.1L marine engine, 3 core inlet side thermostat sand casting, and other misc. design updates on 6.8L and 8.1L marine and natural gas engines. Pro-E work on test fixtures and misc. other projects. Created plastic styled 9000 series hood louver insert. Updated 8000 series independent front suspension components, and 7000 series IVT rear casting. Assisted the Raptor (8000 IVT) group with Pro-E problem resolution including large assembly management issues. Produced geometry for Raptor hydraulic manifold, with optimized 3 core sand cast gray iron casting, considering demanding packaging constraints, fit up and tolerancing issues. Daily duties are similar to Contract Engineer function at Deere PEC, with increased emphasis on individual organization, Pro-E and Pro- PDM coaching and problem resolution, scheduling and communication.

December 2002- March2004: Proposed improvements, and produced Pro-E geometry for new castings and various components of an air suspension system for rubber tracked tractor, to attain initial costs of parts and assemblies for advanced tractor engineering project establishment. Worked with emphasis to meet ideal suspension characteristics and tractor dynamics. Also performed design work on various projects involving Pro-E models and drawings. PRODUCT ENGINEER July 1992 - September1995

Sears Manufacturing, Value Engineering Dept.

[A suspension seating manufacturer for Ford, Case, Deere, Caterpillar and others] Proposed, design, tested and implemented cost reduction projects totaling over $400,000 in annualized savings while maintaining quality. Logged 500 hours on Pro-E; communicated designs with suppliers, rapid prototypers and customers via Pro-E file transfer. Used value engineering techniques with a team approach, to review seat designs with manufacturing personal through entire design process to anticipate and resolve assembly and quality issues. Derived part and assembly costs for others’ projects. Familiar with Boothroyd - Dewhurst DFMA techniques and software. Designed injection and rotationally molded, vacuum and pressure formed plastic parts, emphasizing snap fits. Also designed die cast, powder metal, sheet metal and formed rod parts and weldments. DESIGN ENGINEER July 1990 - February 1992

Magnum Tractor - J. I. Case Co. Racine Wisconsin

Worked to resolve problems effecting the operation, maintenance and service of the 7100 series Case - I. H. Magnum 2 WD Tractors. Research marketing issues and evaluated overall product performance of Magnum tractors and their competition. As cost reduction specialist, performed detailed design and process reviews on steel fabrications, casting and machining operations, weldments, plastic parts and assembly methods. Worked with manufacturing teams to reduce cost and maintain quality. As file coordinator, checked 3-D CAD Data Base of IBM CATIA CAD systems drawings and models. Produced detailed timing and test plans for these projects, overseeing them from concept to implementation. DESIGN ENGINEER November 1987 - March 1990

Wayne Division - Dresser Industries - Salisbury, Maryland Worked as an effective team member in a manufacturing environment which worked to be a world class business by implementing design for assembly techniques, statistical process control and employee participation groups. Designed and tested gasoline dispensers utilizing aluminum and cast iron castings, linkages, hydraulic hardware, sheet metal fabrications, plastic and structural foam molded parts, lighting and digital electronics, with emphasis on aesthetics. Gained experience with the McDonnell Douglas Unigraphics II cad systems, including wire frame and surface modeling.

MECHANICAL ENGINEER September 1985 - November 1987 Acme Transformer - Lumberton, North Carolina

Designed and tested dry type transformers. Components including sheet metal fabrications, fasteners, structural steel and structural insulating parts. Used MCS - Anvil 1000 MD CAD system.

ESTIMATING AND SALES ENGINEER June 1984 – September 1985 Morton Buildings - Morton, Illinois

Buildings design and estimating work at Morton and Gettysburg, Pa buildings components plants, and sales in Lumberton, NC area.

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