Technical Support Business Development

Mansoor Chaudhry

***** ******** *****, ******, ** 48187 810-***-**** ****************@*******.***

Objective

Seeking a Application Development Engineer position that can utilize my over 20 years diverse Product Engineering, Project & Program Management, Technical Sales, Marketing and Customer Service Experience.

PROFESSIONAL SUMMARY

-Extensive Automotive Energy Management Programs Experience in Technical Marketing of Foam Products for Domestic and International Vehicles.

-ZFTRW/BCS-AIS: Launched Successfully Stalks and CEAs for T1XX, Y2XX and A2XX programs, won new Stalks and CEAs business for BEV-3 and 31XX-2, 1.5 Million Vehicles programs.

-IAC SPRINGFIELD: Successfully Launched Carpet and non carpet Flooring and Dash Insulator for GM programs.

-Chrysler Corp.: Responsible for Design and Release of Overhead System of Jeep Cherokee. Designed and Analyzed Energy Management Systems for head impact protection at Daimler Chrysler PL, PT, JA, JX, LH, TJ, WJ, AN and RS Platforms.

-FORD: Responsible for Design and Release of Soft Trim for Ford Explorer. Performed sled and component testing of FORD Explorer, Taurus, Lincoln and Focus Programs

-GM: Worked as Resident Engineer at GM for ZFTRWCS-AIS, a single person contact for technical support for Stalks and CEAs for T1XX, Y2XX and A2XX Programs.

-Designed, analyzed and tested vehicle structures and countermeasures for head impact protection for GMT900 (Pickup and SUV) Programs and MidLux platform. Designed, and Tested (Development and Validation) vehicle structures and head impact protection countermeasures for GMX211(Impala), GMX245-ZR1(Corvette) and GMX381(G6) programs.

-Fagerdala USA: Managed automotive projects that will need millions of pounds of GECET Foam for energy management applications.

-Createc Corp.: Provided Leadership in Marketing and Fundamental Technical Support for Design, Testing and Coordination of GECET, EPS and EPP Foam Countermeasures.

-Huntsman Corp.: Provided Leadership in Marketing and Fundamental Technical Support for Design, Testing and Coordination of Foam and TPO Automotive Countermeasures.

WORK EXPERIENCE

Sr. Product Engineer – GM Resident, ZFTRW/BCS-AIS – Warren, MI (08/2016 – 11/2019)

Winning team member of BEV-3 & 31XX-2 Turn Signal Stalk and Column Electrical Assembly (CEA), 1.5 Million vehicles business.

Launched Successfully Stalks and CEAs for T1XX, Y2XX and A2XX programs.

Single Person Contact between GM and ZFTRW/BCS-AIS for SCCM Engineering Support and facilitated Management Level Meetings for Current and Future Programs.

Wrote Engineering Work Orders (EWOs, MMOs, ECRs, BCRs and BSDs), provided VCDs and DRBFM.

Reviewed Stalks for AAR Approval and got T1XX, A2XX and Y2XX Stalks Approval from GM Materials Group.

Reviewed, uploaded Test Plans/Results in the CEMENT and got approvals from GM Validation group.

Worked with GM Engineers to get Approval of PPAP Packages for Manufacturing plants.

Supported Pre-Production Vehicle Builds and addressed Quality Issues at Warren PPO South/ AEC Building, MPG and Lansing.

Supported Warranty Review Meetings and worked closely with BCS-AIS Quality Team to address PRTS and perform Root Cause Analysis of Warranty Parts.

Participated actively in the PDT and Engineering Changes meetings.

Tracked EWOs and Pre-Production Parts Delivery for on time completion.

Successfully Completed GM DRE Essentials and Software E–Squared, ECM and CEMENT Training.

Launch Engineer/Senior Engineer, IAC – Springfield, TN (06/2014 – 11/2015)

Managed Launch of Carpet and Non Carpet Flooring and Dash Insulators for GM Programs (31XX, K2XX and GMX211), 60 Million Dollars business at IAC Springfield, TN. Manufacturing Processes included Thermoforming, Insert Foam Molding, Die Cutting, Water Jet and Sonic Welding.

Performed 5S, KAIZEN, KANBAN, Audits, Teardowns, Costing, Development of Tools, Assembly Plant Visits and Directed Prototype Parts Manufacturing.

Ran Mold Trials to select PolyOne PVC as back up material for K2XX and 31XX Dash Insulators.

Improved production of K2XX Dash Insulators over 30% by removing bottlenecks in maximizing the production.

Also improved relationships with GM Assembly Plants by providing excellent service.

Successfully implemented engineering changes for K2XX and 31XX Vinyl Floors and Dash insulators.

Knowledge of PLM, AS400, GM SupplyPower and Prolink software and wrote PFMEA, ECNs and Work Orders.

Overhead System Engineer, FCA. Employer: G-Tech, Dearborn, MI (10/2013 – 03/2014)

Responsible to Design & Release, Solve Product Quality Issues and Reduce Warranty Claims for 2014 Jeep Cherokee Overhead System.

Worked on Technical Cost Reductions projects of over $1.5 Million related to HIC, BSR and NVH Foam, Grab Handles, Plastic Retainers in Overhead System, Velcro Hook, One piece Visor Center Support, Sun Visor, Headliner Substrate etc.

Familiar with Control Plans, GD&T, Gage R&R, Process Capability, Measurement Systems and Root Cause Analysis, Successfully use Data to Identify and Resolve Issues.

Also familiar with Chrysler Software eCIMS, CCD, WebCN, FastCAR2, EBOM and Dashboard Anywhere.

DRE, Ford Motor Co. Employer G-Tech, Dearborn, MI (05/2013 - 09/2013)

A Cost Saving Assignment, Designed, Released and performed Tolerance Stack up Studies of Deployable Hood Lift Actuators for 2016MY Mustang, 2015MY Edge and Galaxy, worked with a Full Service Supplier in leading cost reduction ideas.

Senior Project Engineer, Ford Motor Co. Employer ETA-Troy, MI (11/2010 – 01/2013)

Responsible for Design and Release of Carpet, NVH insulation, Hood insulation and Cargo Management System for 2013MY and 2016MY Ford Explorer.

Loaded test data in eFDVS for 2013MY Ford Escape, Lincoln and Fusion Programs.

Addressed urgent launch issues of 2013MY Ford Escape, Lincoln and Fusion Programs.

Familiar with TCE, AIMS, Vehicle Attributes, Material and Color Approval Process, GD & T, WERS, CAE, AVBOM, DVP&R, DOE, APQP, PPAP, ISO9000/TS16949, DFMEA, Six Sigma and have experience to develop a Continuous Improvement Process Flow chart for Head Impact Protection Countermeasures

Performed Sled and Component Testing of Safety and Load Carrying Components of FORD Explorer, Taurus, Lincoln and Focus Programs.

Supported Safety/Crash Department in their effort to meet Federal Safety Regulations for FORD Explorer, Taurus, Lincoln and Focus Programs.

Managed a team of engineers and a budget of $10 Million for procurement of Safety/Crash parts for three platforms at Ford Motor Co.

Consultant, MCP, Automotive Engg. & Sales Co., Windsor, ON (06/2008 – 11/2010)

Provided Technical Sales and Marketing Support to Fagerdala USA Inc. GECET Worldwide Business.

Provided Design and Development services to Global Enterprises in selection of core foam for JC49 and Chrysler XK Jeep Load Floor Programs.

Worked with Valley Enterprises on Cost Saving Projects for GM Lambda and HHR Load Floor Programs.

Performance Engineer, GM Tech Center, Employer: Aerotek-Troy, MI (05/2007 – 06/2008)

In a Continuous Improvement project, designed, developed and tested Head Impact Protection solutions for GMT900 (Pickup and SUV) Program

Designed and Tested (Development and Validation) vehicles structures and Head Impact Countermeasures for GMX 211 (Impala), GMX245-ZR1 (Corvette) and GMX381 (G6) Programs.

Developed a Continuous Improvement Process for GM Head Impact Protection Countermeasures.

Product Engineering Manager, Fagerdala USA Inc. Marysville, MI (03/2004 – 03/2007)

-Worked with the largest Tier 1 supplier on projects that will replace PU foam with GECET Foam in the steering wheel for GMT900 program, a 1.3 Million dollars project.

-Worked with GM and Draexlmaier Engineers to successfully design, develop and launch energy management foam for passenger knee protection of 2008 CRX program

-Quoted JCI 17 Million dollars energy management foam for truck programs at Daimler Chrysler.

-Successfully launched GECET core foam load Floor for Ford Explorer and worked on the development of Load Floor and Tire Cover with GECET Foam for 2009 Expedition and Mustang programs, 5 Million dollars projects.

-Worked with the largest Safety component supplier on projects that will need millions of pounds of GECET Foam for automotive safety applications.

-Helping a Block Foam Molder to mold GECET Foam for composite applications in auto and non-automotive markets.

-Worked with a major Tier 1 Supplier on the development of head restraint system to comply FMVSS202A for an OEM.

-Managed Projects that will need millions of pounds of GECET Foam for automotive applications.

-Provided Marketing and technical support to GECET foam business in the automotive industry all over the world. The technical support included design, material selection, development, testing, data analysis, quality and safety.

-Published a new GECET Foam brochure to reintroduce it in the automotive and non-automotive markets.

-Strengthened business relationships at OEMs, Tier 1s and molders by providing excellent technical and sales support.

Applications Development Engineer, Createc Corp., Clarkston, MI (08/2002 – 03/2004)

-Provided Marketing and technical support to EPP, EPS and GECET foam business in auto industry. The technical support included design, material selection, development, testing, data analysis, quality and safety.

-Opened new accounts at Willis Manufacturing, Casco, Valley Enterprise and Industry Products Company.

-Strengthened business relationships at Honda, GM, Ford, DCX, Lear Corp. JCI, Magna, BBI and Midway Products by providing excellent technical and sales support.

-Established new contacts at Visteon, Delphi, Grupo Antolin, Draxlmaier, Faurecia, Venture, Azdel, Crotty Corp., Bentler Automotive, Flex-N-Gate, Pullman Industries, Shape Corp., Toshiba, Guardian Automotive, Narmco Group, Lake Side Plastics and NYX Corp.

-Worked with Lear Corp and JSPI to jointly design EPP foam Headliner with energy management countermeasures for interior head impact protection.

-Worked hands-in-hands with resin suppliers JSPI, BASF, Huntsman Corp., Nova Chemicals and GE Plastics to develop and market automotive foam products.

-Saved thousands of dollars by collaborating with Georgia Pacific, in Marketing and testing Load floor.

-Worked with consulting firms and test labs, Easi Engineering, Altair Engineering, Hoff and Associates, MGA and Detroit Testing Lab. Inc. to promote Createc Corp. in automotive industry.

Applications Development Engr., Huntsman Corp., Auburn Hills, MI (09/1997 – 08/2002)

-Provided Marketing and technical support to GECET foam business in auto industry. Marketed GECET foam so successfully that Daimler Chrysler RS, JR, AN, DN and KJ platforms selected it material of choice for upper interior head impact protection.

-Developed two energy management designs that are 40% more efficient than a solid piece of GECET foam.

-Tested GECET foam with different designs, thickness and densities. Based on this testing, developed a guideline for the use of GECET foam for Upper Interior Head Impact Protection.

-Co-ordinated the Analysis of softwall, developed by a Major EPS Molder, using finite Element Method. Potential applications for this softwall are car race grounds and electric poles in the cities.

-In last three years, Presentations were made at OEM (GM, FORD, and Daimler Chrysler), Tier 1 (Lear, Delphi, Visteon, JCI, and Textron) and Consulting Firms (Easi Eng., Altair Eng., Engineering Technical Associates, Hoff and Associate) to market Huntsman Energy Management Materials (GECET, PU, TPO and PE). Met with more than four hundred engineers during this campaign.

-Selected AP-7310-HS as head impact protection TPO material for AN Program in 1998. Now a sale of AP-7310-HS is more than 2 million dollars and is considered one of the best RTPO in auto industry.

-Surveyed automotive testing Labs generated high strain rate and high-speed impact data. Also coordinated finite element analysis activities for Huntsman Corp. PP, PU, EPS and GECET business

Project Engineer, GM & Daimler Chrysler, Employer ETA, Troy, MI (05/1995 – 09/1997)

-Chaired the Restraint Tech Club and Head Impact Tech Club at Daimler Chrysler

-Coordinated the Core Group in Head Impact Tech Club and developed a Foam Matrix and a Plastic Matrix for applications to head impact protection. Familiar with foreign and U. S. safety regulations and test dummies.

-Tested vehicles for foreign and U. S. Safety regulations, and wrote reports. Tested materials/designs, analyzed test data and made recommendations. Also tested and selected energy management materials for head impact protection.

-Worked with material suppliers to select new materials for head impact protection.

-Coordinated the energy management development team to update head impact guidelines for the Daimler Chrysler and wrote the preliminary outline of updated head impact guidelines.

-Helped prepare Product Assurance Plan (PAP) for Head Impact Development in the Scientific Lab Platform of DCX.

-Developed component head impact test strategy for Safety Lab in the Daimler Chrysler.

-Conducted a seminar in Scientific Lab Platform on head impact protection across the platforms in the Daimler Chrysler.

-Developed a head impact development flow chart, presented it in the Head Impact Tech Club. and across the platforms in the Daimler Chrysler

-Made recommendations for crush space requirements for head impact protection in the upper interior components of 2001 PT – Cruiser, including counter-measures material thickness, cross section dimension and material types from foam and plastic matrices. Recommended changes in the inner sheet metal gage of A, B, C and D Pillars which reduced the crush distance required for head impact protection. Proposed new A-Pillar section that will be friendlier for head impact protection. Proposed a plastic trim counter-measure for B-Pillar to replace an expensive design of record foam countermeasure. Proposed two concepts to develop adjustable turning loop (ATL) which will eliminate the need of any countermeasure on and beneath the ATL track. Shared head impact development information from other platforms in the Corporation with the 2001 PT – Cruiser Head impact Countermeasure Development team.

-Tested 2000 PL (Neon) F1 vehicle to evaluate the performance of design of record counter-measures at the impact target points on the right side of vehicle. Also, tested impact target points R-BP2, R-AP2 and R-AP3 for the baseline HIC (d).

-Recommended changes in design of record counter-measures for optimization and further development, including material thickness and material properties.

-Presented head impact development flow chart in the 2001 RS Minivan head impact design/development meeting and 2001 JA design meeting recommended materials and designs to develop counter-measures for Pillars and Headliner.

-Performed test data analysis of a counter-measure used at adjustable turning loop (ATL) for head impact protection on 1998 LH and made recommendations to improve the design. Analyzed the test data for A and B Pillars countermeasures, recommended a rib height at impact target point AP3 on A-Pillar to bring HIC (d) less than 800. For Non–NHTSA impact targets points on B-Pillar, recommended to develop a counter-measure on the slider to meet the FMVSS201 Upper Interior Head Impact Protection Regulation.

-Designed, analyzed and tested head impact counter-measures on TJ-Jeep Wrangler for European Head Protection safety regulation. Used finite element analysis technique to optimize rib height, thickness and spacing between ribs to develop plastic trim countermeasure for head impact protection.

-Performed test data analysis of head impact counter-measures on A-Pillar of WJ Grand Cherokee, made recommendations for rib thickness, rib height, designs and materials for A-Pillar counter-measures.

-Designed and analyzed head impact counter-measure plastic trim on the A-Pillar of AN Truck using finite element analysis technique and recommended the use of foam at Impact Target AP2 where ribs could not be designed.

-Helped to estimate the crush space required at impact target points for head impact protection based on baseline HIC (d) of DN Truck, also recommended materials and designs to develop counter-measures for Pillars and Head liner.

-Evaluated head impact countermeasures, such as sheet metal on roof side rails and plastic trim on A and B Pillars of 1997 Toyota Camry. Performed test data analysis of a sheet metal counter-measure on roof side rail and plastic trim on B-Pillar, presented the data at Head Impact Tech Club. Compared the Chrysler and Toyota head impact counter-measures for impact targets points SR1, BP1 and BP2. Wrote a report on the 1997 Toyota Camry head impact study.

-Performed 1998 PL NEON European compliance tests (ECE R-17 and ECE R-14) and wrote reports.

-Performed 1998 JX FMVSS210/207 development test to evaluate the performance of recliner with change in material.

Project Engineer, Ford Motor Company-Employer DCED, Clawson, MI (08/1993 – 09/1994)

Used Ford software V-CRUSH, Secollapse and Compcollapse for Finite Element Analysis of component model and system model from light weight materials for Ford Vehicles.

Performed Component Level Crash Testing of Unidirectional, Bidirectional and RTM Composites.

EDUCATION

MS in Mechanical Engineering (1989 - 1992)

University of Windsor, Ontario, Canada

BS in Mechanical Engineering (1984 - 1989)

University of Engineering and Technology Lahore, Pakistan

SPECIAL COMPUTER SKILLS

Software: PAM-CRASH, LS-DYNA3D, Altair-HyperMesh and HyperView, Algor, (Secollapse, Compcollapse,V-CRUSH) For Linear/Nonlinear Finite Element Analysis

Teamcenter, NX, CATIA, SMUG, PDGS, AutoCAD, CADKEY, MASTERCAM (FANUC) CAD/CAM, Packages,

Utility Software Such as MSWord, Excel, PowerPoint, WordPerfect, KaleidaGraph, Harvard, Graphics Languages: FORTRAN, BASIC, CNC Programming,

Systems: UNIX, MSWindows, Dos and Novell network

PUBLICATION

-Comparison of Energy Management Materials for Head Impact Protection (SAE Paper No. 970159)

PROFESSIONAL TRAINING

-Designing Plastics Parts and Components by Glenn Beal

-Altair Hyper Mesh and Hyper View for FEA Pre and Post Processing

-WERS and GD&T Training at Ford Motor Co.

-DFMEA and GD&T Training at Chrysler Corp.

-DRE Essentials and Software E–Squared, ECM and CEMENT Training at GM

References Available Upon Request

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