DEAN C. FOLTZ 803-***-****

acyxk7@r.postjobfree.com

**** *. ***** **** ***

Gilbert, AZ 85298

SUMMARY

A senior engineer with diverse project management experience in all phases of product development. Effective in product validation, precision machined components, powdered metal (MIM) components, stamped steel, thermoplastic and thermoset molded parts. Experienced with design for six sigma product design and cross-functional team participation.

EXPERIENCE

Advanced Green Innovation, Chandler, Arizona 2013-Present

Senior Mechanical Engineer (Develop a Kit to convert Class 8 Diesel Trucks to SI CNG)

Injector Design Release Engineer

• Develop compressed natural gas (CNG) injector for a HD diesel truck retrofit kit.

• Injector design to incorporate lessons learned from infant designs and testing.

• Create and maintain drawings for prototype evaluation and RFQ

• Calculate force and response requirements for injector actuator with input from combustion and fuel source constraints.

• Design an injector thermal expansion compensator.

• Design combustion ignition electrodes for advanced combustion development.

• Optimize initial injector components for validation testing.

Navistar, PurePower Technologies, Columbia, South Carolina 2010-2013

Senior Product Engineer (HD Diesel Fuel Injector and Pump Advance Concept Development)

• Lead Lean Manufacturing discussions with manufacturing engineers. Component drawings are updated per manufacturing input combined with structural and CFD analysis.

• Maintain cost summary of injector development, including tooling, piece price, outside services and material.

• Design responsible for key injector structural components. Injector component fit is evaluated with dimensional variation analysis.

• Prepare engineering models for analysis, and validation testing.

• Develop new injector design options with input from decision matrix and performance requirements.

• Develop HD oil pump efficiency improvement concept

CUMMINS Fuel Systems, Columbus, Indiana 2005-2009

Technical Specialist (HD Diesel Fuel Injector Development and Release)

Development lead, Scania 2010 HD XPI Injectors.

• Provided quarterly customer updates including DVPR, DFMEA, technical profile and seven step failure analyses.

• Evaluated fuel injectors that completed test for wear and damage that could cause change in Injector performance.

• Prepared drawings with updated BOM and communicated product improvement status with the Customer.

• Improved injector fatigue resistance using DFSS accelerated life test analysis. Technical profile requirements were met without changing material with avoidance savings of over $1M.

• Product improvement to reduce cavitation and flow change due to cavitation damage on an Injector critical component improved Injector performance and design life.

• Analysis with DFSS predicted injector response time to full open and time required to close with different nozzle flow combinations.

• Worked with supply base to assure robust designs, on time delivery and required documentation.

CALTHERM, Columbus, IN 2003-2005

Senior Project Engineer (Responsible for thermostats used in the marine and recreation industry.)

• Developed new products for emerging markets and/or revised existing products for new applications.

• Worked with customer engineering to define specifications and DVPR requirements.

• Coordinated cross functional activities throughout product launch with improved product performance.

• Prepared weekly APQP reports starting with product initiation and ending with PPAP.

STANT MANUFACTURING INC., Connersville, IN 1994-2003

Engineering Program Manager - R&D (Fuel cap leak detector, Vapor Management valves, Capless Closure)

Coordinated new product activities in advanced product engineering.

• Created solutions for new products and applications resulting in 20 utility and design patents.

• Trained entry-level engineers and supported or delegated activities as required to more experienced engineers and designers.

• Maintained program files with updated DFMEA, PFMEA, control plan, process flow chart, design reviews and engineering change notices.

ENBI (INDIANA), INC., SHELBYVILLE, IN 1992-1994

Production Engineer

Organized 2nd and 3rd production shifts in a start-up rubber and plastic molding facility.

• Provided training for all hourly employees, including machine operation and SPC.

• Developed control plans for adhesive application, rubber molding, assembly and grinding areas.

• Developed routing and cost roll-up for new products.

STANT MANUFACTURING INC., Connersville, IN 1989-1992

Product Engineer

Responsible for original equipment fuel cap line, validation, warranty return, and design improvement.

• Completed cost reduction project with GM on corporate fuel caps resulted in a $1M annual savings.

• Coordinated new product activities with manufacturing, sales and engineering.

• Worked directly with customer engineering at product definition through development providing functional prototype samples and PPAP submission.

• Initiated and supervised drafting and laboratory activities relative to projects.

EDUCATION/TRAINING

CLEMSON UNIVERSITY, Clemson, South Carolina

Bachelor of Science Degree in Mechanical Engineering

• NX7 (Siemens) CAD 3D and 2D, SolidWorks CAD 3D and 2D

• GD&T

• Design for Six Sigma Green Belt

• Management Training with emphasis on Situational Approaches to Leadership

• Awarded over 20 design and utility patents

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