Engineer Manager

Professional Cover Letter

Greetings,

My name is David Maloy and I am a Mechanical Engineer professional seeking a position as a Senior Manager for Project Engineers, Senior Manager for Group Design team, or member of a design team as Senior Design Engineer.

I am a degreed Mechanical Engineer with more than thirty years of experience engineering various products, processes and providing integration of products into other systems. I have extensive knowledge of project planning, development, execution, DV (Design Validation), PV (Production Validation) testing of products, Cause & Effects, D8’s, FMEA, Fish Bone and PPAP/APQP.

Experience and knowledge includes:

Extensive knowledge and experience of product life cycle.

Qualification of product integration via Feasibilities Studies and packaging.

Software tools to design, to validate and create 2D documentation. Software tools such as ProEngineer (CREO) for CAD / CAE and for mold analysis I have experience with MoldFlow.

Various Rapid Prototypes construction, SLA, SLS, 3D Printed Parts, Aluminum / Steel / Wood CNC parts,

APQP (Advance Product Quality Planning)/PPAP (Production Part Approval Process).

Selection and qualifying suppliers and manufacturers.

Supplier quality assurance.

Analysis of internal and external CMM inspection reports.

Experienced as Authorized Manager / Engineer to sign-off on manufacturers for production.

An example of my accomplishments.

OEM manufacturer has a product with high manufacturing cost and high levels of CoPQ. Started with a Fish Bone Analysis and evaluate the product from a design and then manufacturing.

Identified design problem. A client has 2 different assemblies. Each assembly has a unique application. The CNC assemblies have a combined totaled cost of $56.

The best design solution was to resigned assembly (a Plastic Assembly) so the new design would fit and function within the 2 applications, IE replacing the CNC Assembly(ies).

Results of a newly design Assembly. New Plastic Assembly will now fit and function within each unique Product application. Additional benefits of the new design were the ability of the product to be backwards compatible to current installed product.

The new design cost was less than $2. A company savings of $54. The estimated savings per year were in excess of $125,000. The life cycle of the new design has a projection of in excess of 10 years.

With thirty plus years of professional knowledge and experience in various design and engineering disciplines, attention to details, and having an intense desire to “Get it right before production” has resulted in giving me great success with each employer or client. Hence, you have my word, “Our future of working together will see the same.”

Best Regards,

David R. Maloy

David Maloy

1650 138th Ave, Holland, Michigan, 49423

Cell phone 616-***-****

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

Work Experience

Via 3D Design and Engineering LLC

6150 138th Ave. Holland Michigan 49423

August 1996 to present

Job title: Engineering Manager, Lead Engineer

Manager of specific client programs for top OEM Manufacturers acting as supervisor and advisor for 4 other co-workers assigned to active programs. My position functions included Upper Management; such as Sales, Client relations, Manager of Engineering, Manufacturing, Quality Control, Purchasing, selecting manufacturing suppliers.

Clients: Pliant Plastics Inc., Trident Lighting LLC, FKI Automotive LLC, Meridian (Herman Miller), Whirlpool, Automotive Lighting LLC., Magneti Marelli Holding NA., Haworth, and numerous small companies.

Responsibilities: Design and engineering and release responsibilities for each client:

oRFQ: Planner for Design and packaging of RFQ for Clusters, Head Lamps / Tail Lamps, Infotainment Systems, etc. Responsible for NDA (Non-Disclosure Agreement).

oPackaging Studies: Responsible for primary packaging studies while RFQ is Open. Coordinated and compiled specification for project and submission to Client.

oDesign Specification Verification: Responsible for working with clients with their design and manufacturing specifications.

oEngineering Concept Phase: Responsible for Studio designers during development of designs. Often this would include the early preparation for DFMA. These would include mechanical and electro-mechanical components.

oEngineering CAD and CAE: Responsible for planning of 3D and 2D CAD. Systems include ProEngineer (Creo), CATIA, UG. Responsible for CAD design engineers’ functions: Design reviews, 3D reviews, Gaps and Tolerance Studies. Responsible for CAE; Reviewed load constraints, Forces, and Stress and Strains. Responsible for review and analysis of Thermodynamics via CAE software. Responsible for the results of all CAD and CAE.

oPrototypes: Responsible for construction of Prototypes. SLS, SLA, CNC machined, 3D printed, and others. Responsible for prototypes testing.

oDesign Validation: Responsible Engineer for selection of suppliers for production components and or assemblies. Responsible for working with selected Manufacturer on tolerances and manufacturing methods. Responsible for the Fit and Function of components. Responsible Engineer for complete testing of components and or assemblies. Responsible Engineer for any corrections to design.

oProduction Validation: Responsible Engineer for execution of manufacturing assembly line. Responsible for First Piece Inspection reports. Responsible Engineer as the Sign-off Engineer. This would include working with client to established minimum and maximum for

oAdministration: Responsible for reporting to Client and upper management the status of project. Responsibilities include cost and timing of project. .

oSupplier Assurance: Visited manufacturers domestic and abroad to survey initial qualification of supplier and final visit for component or assembly customer sign-off for production. Suppliers were located in USA, Asia, and Europe.

(Note: Employers from 1980 -1996 available upon request.)

Education

Orangeburg Technical College

Graduated 1987

Bachelors of Science Mechanical Engineering Technology; graduated 1987, Orangeburg Technical College Orangeburg South Carolina. (Attend multiple colleges and universities in various states)

Achievements/Awards

oASME Y14.5M GD&T Certificates. Received certificates 1994, 2012.

oCertificates in Basic, Advanced CAD (ProEngineer, CATIA).

oCertificates in structural FEA (Creo Simulate).

oReceived acknowledge for “Best supporting Engineer” from Herman Miller Holland Mi..

oReceived an award as company “contract employee of the month” from Magneti Marelli Holdings Auburn Hills, Mi.

o3 Patents: 1 Patent Design, 1 Patent of Product Trade Mark, 1 Patent on Utility.

oSuccessful Business: 95% or more of Clients have chosen Via 3D Design and Engineering as their Product design and engineering.

Skills

oProficient in CAD, 20 plus years of ProEngineer / Creo.

oCATIA V4 12 years and CATIA V5 approximately 2 years.

oWorking knowledge in the use of MathCAD .

oAdvanced training in Microsoft office products, Access, Excel, Word, Outlook.

oManage people well.

oCommendable work ethics and a contagious mental attitude of “Do the job right the first time.”

oAs a Senior Engineering Manager, my goals are to mentor the aspiring Engineering professionals.

Professional References

oMarc Sietsema

oCompany: Haworth; Title: Walls Installation Site Leader

oEmail: ****.********@*******.***

oPhone: 616-***-****

oNathan Lowery

oCompany: Haworth: Title: Product Manager II

oEmail: ******.******@*******.***

oPhone: 616-***-****

oJohn Campbell

oCompany: Haworth (Contract Engineer): Title: Cost Reduction Engineer

oEmail: *************@*******.***

oPhone: 616-***-****

Appended; Plastic Experience of David Maloy

Plastic Experiences:

Experiences with Polycarbonates, Acrylics, Polypropylenes, ABS. Some materials were Talc Filled, Glass Filled, Optical, and all had some form of UV and fire rated design requirement per OEM.

oComponent applications included Automotive Interiors, Exteriors and Consumer Goods.

Material may have had some form Painted and Unpainted process requirement.

Secondary manufacturing.

oPainting of plastics.

oVibration welding of plastics.

oUltrasonic welding of plastics.

oCold heading of plastics.

oHeat Staking of plastics.

oVacuum Metalizing.

Injection molding experiences:

oOver-molding, Two (2) shot injection molding.

oWork with Tool Designers for design improvements before production of plastic part(s).

Types of Molds

oSingle cavity, Multi-cavity.

Insert molding.

MUD (Master Unit Die) types insert molding.

Experiences with Inspections of Plastics.

oCapable of approving plastics parts from inspection, these approvals are based on OEM Quality Specifications and maybe based on agreements between OEM and supplier as “Master sample”.

oCMM Inspection reports.

Capable of analyzing CMM reports. Analytically capable of determining if areas that do not meet design may be granted a deviation or approving non-compliance area as “OK for production, Area or dimensions do not have significant properties to production.

Experiences with Quality Assurance trouble-shooting.

oCapable of gathering detailed analysis from other departments and making analytically decision of Root-Cause deflects, and document Root-Causes and review these analyses with OEM / Client.

More detailed experiences may be reviewed during interview.

Appended; Sheet Metal Experience of David Maloy

Sheet Metal Experiences

Sheet Metal Materials

oCold Roll Steel, Electroplated Galvanized Sheet steels, Hot Roll Steels.

oAluminums, primarily for heat sinks.

oStainless Steel primarily used in applications where high resistance to corrosion is required. Also used for cost effect conductive applications, example Automotive exterior and interior lighting.

oCopper, primarily used for high conductivity applications, such as PC Board Grounding strips.

Sheet Metal Materials thickness

oCommon thickness from 0.5mm to 3mm thickness.

Experiences with tools for Sheet Metal development.

oFabricated Tooling.

Such tools typically perform limited operations. Such as CNC Punching and Press Brakes.

Costs are typically high for fabricated tooling as the processes involves extensive labor.

oSingle Stage Tooling.

Single die set which typically processes a limited number of die operations.

Variable costs are associated to Single Stage Tooling.

oPermanent Stage Tooling or Multi stage Die Set Tooling.

Such tools typically have multiple die stages where each die stage performs specific functions and the machine operator has to move the sheet metal from die set (stage) to die set (stage).

Variable costs are associated to Permanent (multi-stage) Stage Tooling.

oProgressive Die Tooling.

Such tools typically have complete capabilities. From managing entry of raw stock, drawing sheet, piercing holes, trimming edge of steel, forming flanges, and finally part separation from material stock.

Costs associated to Progressive Die Tooling are low as only periodic maintenance are required.

Experiences with Secondary operations.

oRework of parts to eliminate scrapping of out-of-spec parts.

oUse of secondary tools to fabricate prototype parts.

More detailed experiences may be reviewed during interview.

Appended; Die Cast Experience of David Maloy

Die Casting Metal Experiences

Experiences in Zinc and Aluminum Casting.

oMaterial such as Zamak 3 (for light structural requirements), ZA27 (used for low cost heat exchanges or heat sinks)

Casting thickness

oZamak 3; wall thickness at 3mm - 5mm (limited structural requirements).

oZamak ZA27; wall thickness at 2.5mm (extruded heat sink).

Types of Tools for Die Cast Metal development.

oSecondary drilling and or Tapping operations, milling flat surfaces.

oDe-burring (vibratory) or trimming (punch dies) of raw die cast part(s).

Die Cast Plating.

oDecorative Chrome plating.

More detailed experiences may be reviewed during interview.

Using Die Cast designs as heat sink components. IE Zinc or Aluminum have cost effective properties for Thermodynamics transfer. These materials are suited for cold and heat transfer media.

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