Design Engineer Mechanical
Resume:
THOMAS HOWELLS
*.*.*******@*****.***
No relocation. (No GM, Stellantis, GDLS, BAE)
Detroit to Ann Arbor OK, (Ideal West of Detroit).
CAREER SUMMARY:
Warranty Engineer/Product Design Engineer with extensive and diversified Body & Powertrain Engineering experience.
Proven track record, styling, Design and Release, safety products and campaign prevention.
Demonstrated ability in advanced engineering standards, preventing failure modes, inventive design solutions and verification metrics.
Experienced in vehicle structure design and component packaging to establish FMVSS, European, Japanese and other corporate requirements.
Accomplished design engineer with a solid knowledge of design layout and detailing product specifications.
Accomplished team builder and technology leader.
EDUCATION / TRAINING / SKILLS:
BSME, Mechanical Engineer - Wayne State University, Detroit, MI in 1974
Certified Six Sigma - Green Belt
Stress and Fatigue Analysis FEA, CFD (window moldings & exhaust sensor flow positioning)
Analytical Warranty Systems - data mining NOx sensors in Excel pivot tables
CAD: CATIA v5, UX, Siemens Teamcenter capability, C3P ‘digital buck’, Vis Mockup, IDEAS, UG-SDRC, Metaphase, GD&T, ASTM Y14.5M
MS-Office, Word / Excel / PowerPoint, Adobe Illustrator/Pantone colors, C++, DOS, HTML
Cost analysis, VA / VE, Benchmarking. Heat Treatment (latches), Thermal packaging.
Global Product Development System (GPDS), DVP&R, DVM, Knowledge base engineering, Standards author.
Advanced Product Quality Planning and Control Plan (APQP/PPAP), McBeth light booth color approval, grain approval.
Certified on Ford North American Automotive Quality Core Competencies –12 APEL certifications: Global 8-D, Systems Engineering Fundamentals, Product Reliability, Statistical Engineering, Statistical Process Control (SPC), Robustness: Parameter Design & Tolerance Design, WERS change control, FMEA-Express, Fastener and Joint design, Process Control Methods, DOE – ANOVA, Applied Customer Focus, Hazardous material handling, ISO 9001:2000.
Have a Class A Commercial Driver’s License (CDL) and 2 years OTR experience since 11-26-2008.
PROFESSIONAL EXPERIENCE:
KELLY SERVICES, Dearborn, MI Contractor
Ford Motor Co. Jan 2013 – Jun 2023
Application Engineer
Powertrain Controls Application Engineer for ECMs in ICE and Hybrid Electric Vehicles.
Initially was Release analyst for calibration releases for new hybrid and combustion engine applications worldwide.
This simulation includes creating models for the Powertrain and ECU, simulating their interactions over the CAN bus, and analyzing the system's behavior. Analyzed Vehicle logs taken with Vector CAN.
Expanded job skills into all controls as a design and packaging engineer, Create Bill-of-Materials, of all powertrain modules and sensors. Turn program assumptions into cost-able RFQ quotes.
Created an optimized and customer-centric approach to warranty reviews, and quality audits thereby ensuring that customer goals are prioritized and put into action.
Provided warranty technical support and collaboration for quality and engineering groups.
Lead finance team to work with internal and external CAD support Teams in Mexico, India, Europe and Australia.
Worked with Core technology engineers on oxygen, pressure, temperature, nitric oxide and particulate matter sensors applications to meet international emission regulations.
Allocate components to meet emission regulations and marketing features to apply to the correct vehicles.
Managed water issues affecting electronic modules on the C2 prototype build and launch.
Worked on the CFD team to reposition oxygen sensors for improved emission (OBD) monitoring for individual-cylinder traceability, AIR Fuel Ratio Monitor (AFRMN).
In general positioning oxygen and NOx sensors (and coolant sensor) placement in tube depth sleeves to achieve optimal readings. Both pitot and venturi effects are drivers for exhaust flow.
These all complimented my Major in combustion and emission BSME degree.
FORD: Responsible for overall direction and priorities of the warranty organization in concert with the quality organization.
ASG Renaissance, Madison Heights, MI. Contractor at: Navistar Defense
Navistar Defense April 2011 – Dec 2012
Body Engineer / Armor Engineer
Design armored military demonstration TSV vehicles and support ongoing product development for Mine Resistant Ambush Protected (MRAP) vehicles.
Experience in providing heavy armor design solutions with vehicle level, systems and component release experience.
Design various components as power door closures, blast mitigating seats, electrical wire routing and blast countermeasures, lighting, cross-member and trim.
I support both British Ministry of Defense and US Department of Defense projects. Have ITAR and EAR security experience.
KELLY SERVICES, Dearborn, MI Contractor
AWTC - AISIN Nov 2008- Jan 2009
Provide safety backup to technician and take readings in the lab and test cells.
Hyundai Motors (R&D) projects Jul 2008 – Aug 2008
Document Hyundai’s U.S. Research & Development (R&D) projects to take advantage of IRS tax credits.
This consulting project increased Hyundai’s cash flow by ensuring they take full advantage of the IRS R&D Tax Credit.
Actively managed the financial data of quality exposure, setting aside appropriate reserves, budgeting for warranty-related expenses, and continually monitoring financial forecasts.
My actions provided improved interface between finance and various Engine/Transmission/Structures/Hybrid design engineering activities and detailed their verbatim comments.
I further solicited sample reports or Engineering Research projects and drafted an executive summary to provide evidence of Hyundai’s US R&D required for audit documentation.
Ford Motor Company, Dearborn, MI 30.5 years Sept 1976 – Feb 2007
all that follows as a Product Design Engineer =PDE)
PDE - Latch Engineering Jan 2002 – Feb 2007
Served as advanced engineering standards author on hood latch, cable and closure systems.
Consulted with application engineers on issues, reviewed potential failure mode analysis (FMA), proposed inventive design solutions and verification methods.
Experienced in ergonomic and vehicle packaging. Familiar with FMVSS, Japanese, European crash and Pedestrian Protection to establish Global Testing Regulations and documented new consumer testing plans for the North American Market.
Worked with technical specialists on (stress – strain) FEA model. For NVH, fatigue and crash impact countermeasures.
My supplier used CFD to manage multiple (durometer) streams of plastic extrusion moldings. Bright (internal foil) and black tooling.
SDS author creating Design Verification methods to validate regulations or customer Requirements.
I started a Master’s degree with C++ scripting language. I had Assembly language and CATIA v5 training.
Joined program Green Belt project to resolve presenter development problems on the MY 2003 Lincoln Town car & Aviator resulting in compliance with FMVSS113 and updated DFMEA.
Successfully directed the supplier to develop a mass spring damper methodology to resolve the issue and develop an AVI virtual CAD model of a mass/spring/damper system to simulate the functioning of the latch.
Selected by Chief Safety Engineer to establish validation for crash criteria in agreement with affected legal activities for hood latch and hood closure integrity for use in vehicle certification.
Developed patentable concepts on the VIA sled that resolved IIHS 40% offset hood crush and retention.
Incorporated CAE methods to explicitly use hood crush models for crash and developed component design alternatives using CAD. A 2-hood latch design or corned catch hypothesis got the program closures supervisor and CAE/FEA supervisor to support my sled verification methods.
Avoided a recall with a revised heat treat and manufacturing processes.
Eliminated hexavalent chromium by investigating alternate material coatings on three corporate latches that also improved latch efforts and fasteners capability.
Interfaced with other Specification authors on hood requirements and test methods.
Helped the body technical specialist explain how to design the hood over-crown(strain) and hold down force(stress) using FEA model to design the hood margin and over-slam functions.
Resolved D219 and F-series hood deflection and margin hood setting issues using Black Belt front end build tolerance study and Supplier hood margin & deflection projects.
Served as Design and Release Engineer on base latches, release cables and consultant to programs for durability on secondary latches resulting in an improved ergonomic package and functional efforts.
PDE Oct 1998 – Jan 2002
Body Safety Label Engineering, (outgrowth of Restraint Engineering tasks)
Served as Design and Release Engineer for multiple safety and regulated labels for airbags, restraints and rollover for interior and exterior applications and certification.
Interfaced with program engineers on product strategy, technical placement requirements and program control.
Created process chart used by multiple vehicle programs that coordinated labels and reduced label recalls and waste. Made a website with pictures of all label applications.
PDE Dec 1987 – Oct 1998
Inflatable Restraint Engineering,
Coordinated management reviews for technical specialist in airbag technology and chaired weekly vehicle design reviews.
Managed body engineering and cross carline program development and the daily film reviews maintaining a $2.5 million weekly crash program budget.
Served as Project Manager of airbag portion of the first Ford Inflatable / Rollover Curtain Project that resulted in acceptance across all car lines where applicable.
Served as Design and Release Engineer expert and Program Activity Team Leader for driver, seat mounted side airbag and curtain airbags.
Achieved Ford’s first application of side airbags on Windstar minivans.
Perfected the airbag deployment through seat covers.
Driver/Steering wheel with integral horn switch D&R engineer.
Launched driver airbags in three steering wheels at eight plant locations in one year.
Developed TPO and soft touch paint to replace Rim/Scrim covers; saving $7/veh.
Conducted DVP&R on inflatable curtain technology to establish concept readiness.
Served to train application engineers’ implementation readiness to establish cost and feasibility targets.
Used marketing data to create Brand pricing strategy for standard and optional use.
Design leader for side airbag concept and implementation readiness.
Exceeded Taurus Chief Engineer expectations with a complete bill of materials and cost estimates including design proposals for adjacent subsystems.
Interfaced with cross functional engineers to determine cost and extent of changes to subsystems resulting in support for the project.
Served on the team that developed a Rollover test methodologies project that developed reliable, repeatable test methodology. Received the Henry Ford Technology Award.
Established and chaired a cross vehicle line design forum that disseminated curtain technology, including shatter resistant trim materials and seat deployment seams.
Directed airbag traceability project charged with reducing safety risk and resulted in the business plan that identified effected vehicles and verified a potential save of $36 million in inspection cost.
Project was expanded into powertrain traceability for greater quality & savings.
PDE Mar 1987 - Dec1987
Body Engineering – Glass & static Sealing
Released an extruded PVC molding on glass as a modular design that saved up to $25 per car on T-Bird/Cougar and Tempo/Topaz.
Helped German supplier explain Computational Fluid Dynamics (CFD) technology and timing to management to achieve cost savings. Maintained a fleet of 17 DVP&R test vehicles to validate running change.
First application of the dual durometer extrusions was co extruded with aluminum strengthening inserts
PDE Sept 1986 - Mar 1987
Closure Engineering – Dynamic Sealing
Implemented new more effective dynamic door seals and drip lip on Tempo/Topaz one-piece stamped limousine doors and launched them at Oakville Assembly plant.
Analyzed extruded / welded in frame versus stamped door attributes.
Lengthened weather-strip durability life by testing new coatings.
PDE Aug 1982 - Sept 1986
Exterior Ornamentation-Large RWD Programs
Led pre-program design as a program carline engineer (now essentially a PMT leader) for all areas of body engineering. Prototypes build plan coordinator for all Body Engineering Exterior Ornamentation and managed all development issues. Delivered multiple carlines with major freshening content over multiple model years. Managed all open issues and cost risk and opportunities for all body engineering departments that included latch hardware and sealing.
Received the Motor Trend car-of-the-year award in 1985 for a seemingly carryover T-bird sheet metal for freshened front and rear end treatments, electroluminescent lighting and grille cooling requirements
Improved Fascia openings size and placement to resolve supercharged engine cooling airflow and provide license plate mounting.
Developed Aerodynamic flush side door glass & glass runs.
The first bumper wheel-to-wheel opening rear fascia (Taurus/Mark VI/RWD vehicles).
Applied PVC undercoat in wheel splash panel areas to reduce paint erosion.
PDE Sept 1976 – Aug 1982
Body Shell Systems Engineering
Lead pre-program design in body shell and under-body structures architecture and design.
I developed component tooling manufacturability, die model and assembly feasibility.
All component design (primarily lighting, bumper/covers and ornamentation) had to be compatible and integrated with all our sheet metal development.
Developed federal bumper protection bands and heights for initial clay model themes.
I designed all pre-program ornamentation components to establish program component BOM assumptions, and to establish program business model cost objectives.
Developed section shapes and structural beam deflection, and fatigue calculations to meet durability from plotted sections and NVH objectives.
Developed sheet metal draw capabilities, welding and assembly feasibility to support styling Clay model development.
PRIOR NON-FORD POSITIONS:
Detroit Water & Sewerage Dept. 06/76 - 09/76
Mechanical Engineer
General Tire & Rubber Co.) 10/75 - 05/76
Sales Engineer (temporary/contract
Prototype & production tooling development of the first bumper fascia with the chief engineer.
Rubber plant and paint release experience.
Valenite / Valeron Corp (GTE). 10/74 - 07/75
Draftsman – detailer. Machine tool holder
Detailer or Carbide Insert inserts and tools for CNC
Machining and Turning divisions.
Chrysler Corporation Corporate 06/72 - 09/73
Material Control Expediter
(College summer job) Reported on tooling status and part availability including painting progress.
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