Engineer Engineering

DAVID H. DALY

**** ***** ****, *********, ** ****8

Home / Cell: 248-***-****

Email: acvypo@r.postjobfree.com

LinkedIn: http://www.linkedin.com/in/daviddaly

SUMMARY OF SKILLS

Senior Engineer with 25+ experience in Automotive and Defense product development and testing

Expertise in testing & validation of Seating, Safety Restraints, Powertrain & Steering.

Powertrain design and development.

Customer Focus and international experience.

Understanding of metallurgical principles, materials, and mechanical engineering.

Experienced operating dynamometers, spin stands, static durability servo hydraulics, tensile testing, environmental (environmental chambers), life-cycle durability, corrosion, impact, barrier testing, Servo Sled equipment to FMVSS 209 standards, strain gauging, transducer preparation and calibration, and computer data acquisition systems.

Passion for learning

Rapid adaptability, flexibility

DVP&R’s, 8D’s, ESIMs, CN’s, ED&D’s, CCD’s, BOM, prototype control plans, purchase requisitions, key product characteristics, and work orders.

Proficient at all MS Office software and various proprietary software for data acquisition, presentation, and machine control.

EXPERIENCE

4/16 – 7/16

5/15 – 10/15

07/14 – 01/15

01/13 – 11/13

10/11 – 08/12

03/10 – 07/11

Tenneco (Contract through Bartech) – Monroe, MI

Sr. Test Development Engineer

Responsibility to support the Engineering Services group in Monroe, MI. Analyzing new test methods for feasibility on existing test equipment, adapting current test equipment to run new test methods, design and manufacture of new test equipment, design and manufacture of fixtures to support testing, validate performance of new test equipment and test setups, and documentation of all activities. In addition required to lead the maintenance and repair of existing equipment. Also working on strategic projects for Tenneco in the areas including, but not limited to, advanced test method development, conformance to Tenneco and regulatory EH&S standards, and global standardization. Performed damper metric studies on more than 200 test samples, doing more than 1,000 individual tests.

Interfacing with test technicians, calibration technician, in house software developer, other test development engineers, and application engineers to aid in test setups, data collection, test stand optimization, and ensuring test equipment meets required needs.

Excellent program management skills

Performed dyno testing with servo-hydraulically controlled test machine/controls, MTS 407 and/or 458 controllers, MTS Flextest GT and/or Flextest 60 controllers and software

Experience integrating electronic stimulus/response and data acquisition equipment to mechanical and environmental test platforms

Ability to combine varied requirements into a cohesive system

Ability to develop preventative maintenance plan

Basic understanding of PLC’s

Working knowledge of CAD and basic machining processes

Familiar with ride control products and vehicle suspension system

Reading, interpreting, and executing test specifications

Strong analytic skills required, ability to generate engineering analysis programs and perform spreadsheet calculations

Eaton Corp. (Contract through Acro) – Southfield, MI

Lead Test Engineer – Hydraulics Lab

Technical testing & test development position, which engages in planning, supporting and heading-up prototype testing including data reduction & results documentation of prototype CNG delivery system.

Lead prototype testing: Test planning, support technician test build-up, test support, result communication, data reduction & result documentation.

• Worked with onsite resources to setup and execute testing.

• Worked with engineers and technician at location.

• Support product concept design and fixture design.

Strong problem solving skills, testing experience, able to present test plans, updates, and results to a technical team.

Molex Automotive - Auburn Hills, MI

Senior Test Engineer

Perform validation planning and testing on automotive connectors. Write DVPR’s, test timelines, and reports. Attend engineering team planning sessions, and participate in reviews.

Chrysler LLC (Contract through TATA) – Auburn Hills, MI (CTC)

Seat Engineer

Responsible for validation testing on 2014 Promaster van. Manage, organize, and oversee NAFTA integration testing. Saved $10,000 through review and optimization of DVPR.

Wrote engineering reports for engineering specifications and documentation, including DVP&R’s, 8D’s, ESIMs, CN’s, ED&D’s, CCD’s, BOM, prototype control plans, purchase requisitions, key product characteristics, and work orders.

Reviewed and approved engineering designs. Reviewed, approved, completed, and submits required change notices (CCD’s & CN’s) to ensure design outputs meet design criteria.

Assigned to increasingly complex components, sub-assemblies and systems. Responsible for changes based on new requirements or packaging constraints.

Contributed to the application of new technology.

Coordinated the complete development for the 1st row seating. Including outsource testing.

Incorporated Chrysler requirements, regulations and product specifications into the design, ensuring compliance with operational, cost, timing, safety, reliability, quality, and manufacturing feasibility parameters.

Analyzed products and formulated engineering conclusions by the application of engineering and/or mathematical principles and tools.

Consulted and collaborated globally (Fiat group and Chrysler Mexico) with personnel in various engineering and design activities relative to product development and production requirements.

Conducted global conference calls daily and as needed within the project team and supplier, manufacturing and quality communities with guidance from engineering management and senior engineering personnel. Maintain all appropriate documentation.

Provided engineering direction and support to supplier and internal associates. Participated in seat comfort evaluations, and provided engineering recommendations. Utilized CAE tools (NX/Team Center/Vis Pro) to evaluate seats, cut sections, isolate components.

Supplier communication / co-development

Manufacturing communication and support

Defining and documenting Test procedures and specifications

DVP&R creation and management

JCI AUTOMOTIVE (Contract through Adecco) Plymouth, MI

Research Writer / Engineer

Support the product validation process by reviewing, analyzing, and summarizing test data.

Use existing computer tools to develop test reports and ensure that these test reports are developed accurately and in accordance to published and/or provided specifications and requirements.

Responsible for the writing of test reports required to support the various seating development programs.

Responsible for the review of raw data (includes graphs, photos, video, and measurements).

Develop data tables to consolidate and summarize results as required.

Conduct preliminary evaluation of test data and compare to specification requirements.

Work closely with program test engineers or laboratory engineers and technicians to correctly understand specific data.

Expert in the gLIMs system. Authored new standard for photographs.

NAVISTAR – INTERNATIONAL (Contract through MST) Fort Wayne, IN

Drivetrain Engineer

Write driveline codes for release of drivelines into production.

Designed, determine / evaluated drivelines for proper application to each truck.

Designed & conducted driveline testing.

Worked on Medium Duty and Class 8 trucks and developed driveline for hybrid EStar van.

Utilized CAD tools to review driveline installations, wheelbase drawings, instruct CAE designers for changes, review stacks.

10/07 - 2/09

ARVINMERITOR Inc. (Contract through Unistaff) Troy, MI

Test Engineer - Powertrain

Tested Class 8 truck and trailer axles, suspensions, wheel ends and drivelines.

Development and validation testing on military MRAP (Mine Resistant Ambush Protected) & approved to work on ITAR restricted programs.

Utilized dynamometers, spin stands, static durability servo hydraulics, with related instrumentation.

Directed and assisted engineering groups with DFMEA, DVPR, and DOE formulation.

Managed outsource of tapered roller bearing resource testing, supplier competitive evaluation tests.

5/04 – 3/07

FAURECIA Automotive Seating Troy, MI

Test Engineer - Seating

Development testing for first & second row seating on DaimlerChrysler 07–08 Sebring and Stratus

Coordinated test sample & fixture builds for testing.

Analyzed test results and provided recommendations for corrective action on whole seat and component level (structure, foam & trim, mechanisms, electrical).

Managed budget, outsource testing and costs concurrently on first & second row seating programs

Provided regular updates to customer and internal engineering groups

2/04 – 5/04

GETRAG USA (Contract through Spherion) Sterling Heights, MI

Development Engineer - Powertrain

Product development of axle assemblies for GM Cadillac CTS & CTSv programs

Developed the DVPR, dynamometer & spin stand testing

Resolved OEM Customer design and failure issues

Participated in Product Development Team meetings and aided Program Manager.

Wrote test reports and managed outsource testing and costs

2/03 – 12/03

IEE Automotive USA (Contract through CPC) Auburn Hills, MI

Test Engineer – Occupant Detection Systems

Initiated and conducted development testing plans & cycles for occupant detection sensors

Reduced some test timing by as much as 50%

Purchased 62 cu. ft. AGREE chamber w/TSM and negotiated a $20k cost reduction.

Achieved a 40% reduction in outsource test costs

Championed human data collection for seat classification tests utilizing proprietary software

Designed unique fixturing for test programs.

9/99 – 7/02

BORG-WARNER AUTOMOTIVE - TORQTRANSFER SYSTEMS Sterling Heights, MI

Product and Development Engineer - Powertrain

Project Manager for new product development on four-wheel drive transfer case and traction control axle systems (GM, Ford & Honda programs)

Product development testing utilizing dynamometers, spin stands, and road tests with related instrumentation, and data acquisition hardware and software (CAN exposure).

Performed shaft seal DRE functions.

DFMEA development

Supplier communication / co-development

Manufacturing communication and support

Defining and documenting Test procedures and specifications

DVP&R creation and management

Analysis of test and field return parts.

Customer interface and support, as required.

10/98 – 9/99

TRW AUTOMOTIVE Sterling Heights, MI

Test Engineer – Electrically Assisted Steering

Managed validation testing of electrically assisted steering systems for BMW / Rover Programs

Tested products to meet or exceed governmental and customer requirements.

Developed and operated test fixtures and equipment, testing methods and analyzed data

Traveled to the U.K. to evaluate and commonize test methods and procedures with US lab.

6/91 – 8/98

BREED TECHNOLOGIES (aka AlliedSignal Safety Restraints) Sterling Heights, MI

Test Engineer – Safety Restraints (Airbags and Seatbelts)

Managed testing for all GM Truck & Bus seat belt products

Closed-loop and full-scale mechanical testing employing anthropomorphic dummies (ATD)

Assisted General Motors in revising the GMUTS test specification to world-class NAO standard.

Received four company awards for exceptional performance

Developed a cryogenic treatment of SRS materials, solving life-cycle failure problems

Quality group assignment at Mexico assembly plant to assist preparing for QS9000 audit

Designed and submitted for patent an energy management device for seatbelt systems

Engineering Technician – Safety Restraints (Airbags and Seatbelts)

Conducted development and validation testing of air bags and seat belt systems

Utilized tensile testing, environmental, life-cycle durability, corrosion, impact and Servo Sled equipment to FMVSS 209 standards

Developed and operated a world-class benchmarking facility for seatbelt systems.

Designed lead screw shields on Instron Tensile Test Machine, reduced set-up time by 80%.

Performed 200+ cold gas air bag deployments in a 2-month accelerated testing schedule

3/90 – 4/91

GENERAL MOTORS CORPORATION (Contract assignment through Entech Services) Pontiac, MI

Laboratory Technician – Whole Vehicle Product Development

Performed comprehensive vehicle development testing, utilizing servo hydraulic actuators, various instrumentation, MTS programmable controllers, signal amps and conditioners

GM Desert Proving Grounds, Mesa, Arizona supporting hot-weather HVAC development (install, maintain, modify systems and instrumentation).

6/89 – 3/90

DALY & ASSOCIATES Clawson, MI

Engineering Consultant/Owner

Provided a variety of engineering services emphasis on product liability issues (photographic documentation, mock-ups, mechanical teardown, reconstruction and inspection, on-site inspections)

10/84 – 6/89

PACKER ENGINEERING Troy, MI

Engineering Technician

Test design, set-up, vehicle preparation, conducting tests and site inspection throughout the US

Extensive experience including automobile, motorcycle and off-road vehicle crash testing, field inspections, and accident reconstruction

Worked with instrumentation, strain gauging, transducer preparation and calibration, and computer data acquisition systems

Principal participant in design and construction of new Troy office space

Performed cost, design and feasibility review for installing in-house bungee style crash sled.

EDUCATION

SPRING ARBOR UNIVERSITY Troy, MI

B.A. Management & Organizational Development (1995)

OAKLAND COMMUNITY COLLEGE Royal Oak, MI

A.S. Automotive Technology (1991)

ADDITIONAL TRAINING

Spectrum analysis of Sound & Vibration – Bruel & Kjaer - certificate

Principles of Acoustics & The Measurement of Sound – Bruel & Kjaer - certificate

Six Sigma, TQL, TQL II & OFM – various sources – certificate

Weibull Analysis Training – BorgWarner and other sources - certificate

Design of Experiments – various sources - certificate

Statistical Design Methodology – various sources - certificate

Geometric Design & Tolerancing – various sources - certificate

Materials Engineering Training for the Non-Materials Engineer - ArvinMeritor Inc.

Pressure Vacuum Rig Operations – General Motors R&D Lab – certificate

High Speed Photography – University of Wisconsin at Milwaukee - certificate

PROFESSIONAL ASSOCIATIONS

SAE International, SPIE (Society of Photo-Optical Instrumentation Engineers), ASQ

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