Project Engineer Management
Resume:
DARRELL B. SIMMONS
Royal Oak, MI ***** * 937-***-****
****************@*****.***
www.linkedin.com/in/darrell-simmons
ENGINEERING PROFESSIONAL
Accomplished, highly analytical and solution-oriented technical professional with extensive, cross-industry experience supporting various aspects of engineering in the manufacturing, robotic, software, aerospace and automotive industries. Exceptional attention to detail, communication, time management, and problem-solving abilities. Key competency areas include:
Project Management Process Assembly /Efficiency
Product Design Continuous Improvement/Cost Savings
APQP requirements Brazing Processes
CNC Machining Metal Forming – Bending/Stamping
Fuel Systems - Liquid / Vapor Hydraulics and Pneumatics
Proficient in Microsoft/ Google, TeamCenter Cad Hybrid Electrify Vehicles (powertrain)
PROFESSIONAL EXPERIENCE
Stellantis (Advantage Technical), Auburn Hill, MI November 2022 to Current (Contract)
Program Engineer -(DRE)
Responsible for design from concept to production, release, and launch of cold end exhaust components, systems and sub-systems for vehicle programs and worked in cross functional groups for design, validation, procurement, and manufacturing teams. Also, utilized development principles and processes such as: functional objectives, DFMEA, DVP&R and an understanding of corporate and competitive products from a benchmarking, read across and best practice perspective.
Primary Responsibilities
Support the preparation, review, and approval of products / Control documents / Design reviews
Support the management of the engineering design releases for updates and new designs
Support issue resolution and risk mitigation planning and corrective action activities
Support current production and new model launches for manufacturing plant events
Support and work with suppliers to meet Stellantis best practice design requirements
General Dynamics Land Systems (GDLS), Sterling Heights, MI November 2021 to October 2022
(Contract)
Project Engineer
As the Project Engineer my duties include planning and execution of product development for tracked programs. Also responsible for working with product teams to manage the project schedule, cost, processes, and risks for engineering-related activities on the program; as well helped manage large team matrix from functional supporting organizations.
Primary Responsibilities
Assist in managing the project using GDLS processes to meet cost, schedule, and scope
Support the preparation, review, and approval of products / Control documents / Design reviews
Support the management of the Engineering Release Plan (ERP) for Models and Drawings
Execution of assigned daily Control Account Manager duties
Help control the project using Earned Value principles, Metrics, Variance Reports, and changes
Support issue resolution and risk mitigation planning and corrective action activities
Review and approve scope, budget, decisions (technical / project), and formal deliverables
Beaver Aerospace, Livonia, MI April 2021 – October 2021
Project Engineer (6-Month contract)
Assist with the scheduling, planning, forecasting, resourcing, and managing of technical activities to ensure project accuracy and quality. Was responsible for the engineering and technical disciplines of ongoing projects and will establish inspection criteria for the proper implementation of all the elements of a project.
Primary Responsibilities
Preparing, scheduling, coordinating, and monitoring assigned engineering projects.
Formulating project parameters and assigning responsibilities to the most capable employees and monitoring the project team.
Interacting with clients, interpreting their needs and requirements, and representing them in the field.
Performing quality control tasks on budgets, schedules, plans, and personnel performance and reporting on the project's status.
Cooperating and communicating with the Project Manager and other project participants and collaborating with Senior Engineers to create more efficient project methods and to maintain the project's profitability.
Reviewed the engineering tasks and initiating the necessary corrective actions.
Developed specifications for the project's needed equipment.
Created frameworks to measure the project's metrics and data collection.
Establishing field test methods and methods for monitoring the quality of those tests.
Ensured the project's compliance with the applicable codes, practices, policies, performance standards, and specifications.
MHSI, Rochester Hills, MI November 2019 – December 2020
Program Engineer (Packaging Engineer) (Employment duration impacted by Covid)
Managed engineering commodities activities for Chrysler’s pre-launch programs (Modula rack designs used for specialized department on-line assembly programs) including managing design concepts to meet customer’s packaging, assembly, specifications, timing and cost targets.
Primary Responsibilities
• Tracked program timing to assure meeting customer and internal gate events.
• Conducted design reviews with internal/customer team members.
• Supported pre-production event runs at manufacturing plants.
Communicated project and task status to management.
Cooper Standard Automotive, Auburn Hill, MI October 2017 - November 2019
Sr. Program Engineer
Managed engineering activities for fluid transfer product programs (Fuel rails systems for Specialty Engine programs) including fluid product designs to meet customer’s product, packaging, assembly, specifications, timing and cost targets.
• Conducted design reviews with internal/customer team members.
• Reviewed 3D math data with design team and manufacturing engineers (CAD and FEA activities).
• Assessed automotive manufacturing feasibility for prototype and production requirements (DFM&A reviews).
• Conducted supplier technical reviews.
• Submitted DV and PV testing per customer’s requirements (Fulfilling product design APQP requirements).
• Supported run-at-rate events at manufacturing plants.
• Tracked program timing to assure meeting customer and internal gate events.
Usui International Corporation, Sharonville, OH July 2012 - October 2017
Project Engineer
Oversaw feasibility, process planning, launch and daily production for multiple programs including brazing, tube bending, machining and assembly of fuel rails and fuel tubes for high-pressure GDI fuel systems. Work included manufacturing, materials, design and process activities to resolve internal and customer issues for quality, machine capacity, process speed, packaging and other.
• Conducted analysis of product design/changes and created plans to implement these successfully.
• Verified high-quality tube cutting to assure good endforming, in collaboration with machining department.
• Worked with manufacturing group to develop and specify new equipment technology in robotics and high-volume production and inspection techniques.
• Primary customer liaison for design and customer plant quality.
• Developed a 1-piece bracket assembly for high-volume capability, and labor cost savings.
• Designed and installed (w/ Mfg team) the first high-volume power bender with vision system in Ohio plant, saving the cost of two workcells with multiple operators, and increasing capacity.
• Developed advanced endform measurement technology and equipment for 2-side endform sealing to assure endform integrity, reducing high-frequency measurement time (labor).
• Developed a digital information system for each workcell installed plant-wide to have in- cell training, measurement and other information available to front office and off-site for all workcells, which decreased training time and operator errors.
Eagle-Linamar Plant, Chrysler/ Martinrea Joint Venture - Florence, KY April 2010 - June 2012
Resident Quality Manufacturing Engineer for Martinrea-Honsel-Tafime plant in Queretaro Mexico Phoenix Engine program.
Member of the launch team charged with design and build of a new 3.2L cast aluminum engine block. Handled evaluation/approval of quality operating system, validation of measurement system and control plans for engineering specs/material.
• Reviewed and investigated root cause to verify 8D’s, coordinated PPAP/ SREA activities.
• Analyzed product design/changes, identify and implement quality improvements/inspection plans.
• Supported production/manufacturing machining processes to ensure that engine block meets specifications.
Worked effectively as a liaison with Eagle-Linamar plant, Chrysler North-American and Mexico engine plants and Tafime Mexico plant to solve problems/develop solutions; review/investigate inspection failures.
• Applied advanced engineering methods including Six Sigma, Lean Manufacturing, Optimization.
• Monitored and tracked supplier quality issues and delivery schedules to meet launch requirements.
Analyzed crank case failures to reduce porosity in process, resulting in failure rate reduction from 33% to less than 5% (met specs), and increased capacity +8% and cost savings of $160K annually.
Ford Transmission Plant, Sharonville, OH September 2004 – March 2010
Resident Quality Manufacturing Engineer for GKN Sinter Metals, Shanghai Automotive Gear Works and Magna
Powertrain-Pullmatic Manufacturing
Member of the manufacturing engineering team for the 6F/X22 Ford/GM joint venture program to design/build a new 6
speed FWD/AWD transmission. Responsible for multiple product launches, quality, process, design change and cost reduction activities, working with powder metal and stamping products and processes. Oversaw containment and resolution of all quality issues, driving permanent corrective actions at the manufacturing facilities.
•Worked with Ford to develop zero defect strategies for supplier Pass-Thru Characteristics.
•Analyzed product and process designs to reduce overall product cost through capacity increase, labor reduction, material optimization and defect/scrap reduction.
•Worked effectively as a liaison with all departments in Ford power train operations to solve problems and develop solutions; reviewed and investigated results of inspection failures.
•Monitored and tracked supplier quality issues and delivery schedules to meet launch requirements.
•Performed oxidation problems/ rejects including analysis and recommendations led to $200K savings annually.
•Handled excessive part contamination and developed an off-line cleaning fixture to resolve downtime issue, with no process time impact, increased part capacity +15%, saved $120K annually in rework/scrap costs.
•Performed major containment/measurement issue: Certified/Installed gages and did personnel training to address 4 months of inventory, reduced rejects from 46% to 2%, saving $100K in rework cost and $65K in supplier chargeback cost.
ADDITIONAL RELEVANT EXPERIENCE
Morning Pride Manufacturing, Dayton, OH,
Supervisor/Team Leader
Space Age Concepts International, Dayton, OH
Electrical Engineer
LexisNexis, Dayton, OH
Operations & Performance Engineer
Knight Controls, Inc., Dayton, OH
Project Engineer
EDUCATION: Central State University: Bachelor of Science (BS), Manufacturing Engineering
Project Management, Engineering Experience – Resume Outline
As a Program/ Project Engineer at Cooper Standard and Usui Inc. I was responsible for launching multiple fuel line systems including 7 global GDI programs – HP Jumper fuel line tubes (Pump to fuel rail) for Ford and GM automotive companies.
Launched HP fuel System Programs:
Employment
Customers
# Programs
Launched
# Global Programs
Launched
Developed Specialized Equipment
Product type
USUI
Ford
7
5
*Hydro Pulse Tester
*Hydraulic-Power Bender
HP Jumper fuel lines (Pump to fuel rail)
GM
3
2
Hyundai
1
Cooper
Polaris
3
Fuel Rails
Project Management Duties:
Assisted team members in successful completion of projects by providing design and drawing support, APQP documentation support, BOM maintenance, prototype builds, and validation issues
Supported new business development by preparing designs for quoting using standard products and internal best practices
Utilized design best practices to contribute design input on new product development
Executed customer engineering changes on production parts
Interfaced with internal engineering groups and manufacturing teams to assist in the development and execution of new projects
Provided technical support and direction on internal improvement projects
Communicated project and task status to management and critical project stakeholders
Practiced effective team skills by sharing learned knowledge with cross-functional team members
Maintained accurate product development record
Managed and participated in continuous improvement programs for product /process improvement
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