Engineer Design

PROFESSIONAL OBJECTIVE AND PROFESSIONAL RESPONSIBILITY FOR MINTH, HUTCHINSON, HENNIGES & GM

Accomplished Automotive (GM & Tier-1 suppliers) Design Development Product Engineer in body closures, body structures, exterior components electrical components and interior trim. Proven expertise in the following areas: sealing performance, defining design criteria with typical sections for attachments & interfacing components, preferring overlap joints -vs- butt joints, implementing lessons learned, continuous improvements with 8D/5-phase problem-solving reports, improving reductions in (cost, timing, feasibility, weight, warranty, labor, variation), updating change history of design files & component drawings. Successful interfacing with purchasing, prototyping, styling design agreement & Appearance Approval Results (AAR), engineering analysis systems, reacting to variation data from scanning machines & Coordinate Measuring Machines (CMM), reducing general asm ergonomic install efforts, Engineering Trial Run (ETR) impact evaluations to mfg./asm process & asm audit defects from eng chg.

Leading designers, quoting process, sales, mfg material/supplier selections & quality/test engineers. Releasing & updating the following global improvements in GM, FCA, Nissan design files/drawings to optimize: fit, form, function, gap/flush for interior-exterior fits, implementing new technology, gage/tooling with component changes for improvements in check fixture dimensional data results, manufacturing process flow, mold/tool trials, virtual digital buck /proto /ETAC-ITAC buck evaluations /match checks /production launches /PPAP events, mold flow analysis, CAE-FEA form analysis, Red-X studies, mock-up buck evaluations, 3D-SLA new fabricated sample component evaluations, minimize risk, work instructions, inspection instructions.

Using the following composite plastic trim attachments practices: doghouse, keyholes, trim hooks, 3M 2-way tape, heat stakes, insert molded components, high-low threaded studs & ITW metal/plastic clips. Controlling max insertion/min extraction for clip attachment is key to reliability. Driving interior/exterior component harmony for common matl, grain finish, gloss & color.

Solution provider that updates managers with the following written and verbal presentations: weekly meeting includes (agenda, timing, open issues, meeting minutes, inviting/interfacing with team members) for Product Development Implementation Team (PDITs), resolving asm/testing issues per Problem Resolution Tracking System (PRTS) with 5-phase/8D reports, production or temporary Engineering Work Order (EWO) for Approval in Change Approval Board (CAB) with cost-timing-feasibility info, Bill of Material (BOM), creating/updating DFMEAs & ADVP&Rs, Supplier Eng Chg Requests (ECR) with approved supplier Eng Chg Number (ECN), creating/updating Production Asm Description (PADs) documents, retrofitting new fabricated components on test lab property & test vehicle at Customer Proving Grounds to validate durability of a change. Define max/min Compression Load Deflection (CLD) and Insertion /Extraction for sealing performance per testing /best practices /FEA analysis.

CORE COMPETENCIES

Design for Six Sigma(DFSS), GD&T Stack-Ups, PLEX, Microsoft Office (Word, X-Cell, P-Pt, Project), trained in UG-NX/Auto-CAD & Team Center, We-Transfers, Vis-Mock-up, Key Statistical Product Characteristics (SPCs), RFQ’s, PPAP & APQP Process, Document changing design files, BIW, Tooling (Glass/Stamping/Roll-Forming/Extrusion/Injection Mold), FEA Analysis for CLD & Ins/Extraction, BOM (Bill of Material).

PROFESSIONAL EXPERIENCE

Minth North America Engineering, Wixom, MI.

May 2015 – May 2020

Sr. Product Design Eng. for Window/Roof Molding Sealing Systems [Green House Molding(GHM), Roof Ditch Molding(RDM), Outer Belt Molding(OBM)] accomplishments:

Teamwork involvement in quoting process for GHM, OBM, RDM (Nissan, Audi, VW, BMW, Volvo, Tesla, GM, Ford, Mazda, FCA and awarded new business for P42Q/R, H61P, Q5/SB, WS Programs worth $14M in tooling) by defining the BOMs, illustrations, engineering finish/performance specifications, Cross Sectional Area (CSA), mass and process flow/tooling.

Directed Wixom/China designers interfacing to door, window, w/strip, appliques, mirror with end caps (H61P TPV/SS OBMs).

Coordinated Wixom/China designers interfacing to door, window, w/strip & interior trim (H61P C-Pilar ASA garnish molding).

Responsible for $17M tooling feasibility on GMC Acadia, Cadillac SR5, Buick Enclave & Jeep Wagoner (GHM) into production from Minth China to GM Asm (Bright/Black Aluminum Anodizing Options or Bright/Black/Silver Stainless Steel Options) and Chevy Traverse (GHM) into production from Minth Mexico to GM-LDT Asm with the following accomplishments:

Eliminated stamping/belt extrusion joint alignment asm audit defect with plastic 2-shot changes locator ribs & bayonet hook.

Improved asm install efforts of UR-Molding with extra w/strip slip coating, control size of w/strip m-head & molding channel.

Tooled $8M (form/trim stamping dies, PP/TPV rotary 2-shot mold & new machine, 5 station automated machine, Check Fixtures) a full stamping with no joints, outer belt seal attached with heat stakes, a plastic TPV/PP 2-Shot with PP lower B-Pilar flags, optimal mirror interface with TPV Isolator ribs to adjust stamping in/out and locate TPV/PP gate between ribs.

Hutchinson Automotive, Auburn Hills, MI.

October 2011 – May 2015

Product Design Engineer for Closure/Window Sealing Systems: cut-lines, inner belts, Glass Run Channels (GRC):

Nissan Maxima GRC for proto/production with the following development accomplishments:

Released $2M in tooling for TPV/PP(cut-line seals and inner belt seals).

Validated interior fit with cold pour samples to avoid $1M worth of TPV B-pillar mold trim flag changes ($4M program tooling).

No water leak occurrences in Nissan Japan builds and Smyrna Asm production builds (to avoid $1M/year in warranty cost).

Chevy Malibu GRC and Inner Belt for proto/production with the following development accomplishments:

Controlled molding insertion/extraction with increased extrusion checks of “Mushroom Head” and added a retention tab to B-pillar end cap on UR-Molding per $300K/year warranty reduction.

Received Styling Design Agreement on 2016 Malibu quarter stamping Class-A surface with Magna’s encapsulated window.

Henniges Automotive, Farmington Hills, MI.

September 2010 – October 2011

Product Design Engineer for Closure/Window Sealing Systems (Chevy, Buick, Cad, GMC, Saturn) accomplishments:

Reduced LDT Asm ergo install/scrap for secondary w/strip changes to gripper/hider lip profile/durometer ($7K/mo. savings).

Improved carrier retention/fit of RD c-pillar cut-line w/strip per extrusion change ($200K/yr. in warranty/containment savings).

Added more swing clearance for door to fender w/strip with less compression to fender (eliminated LGR Asm audits).

Navistar Corporation, Fort Wayne, IN.

May 2010 – September 2010

Product Design Engineer for body structures (motor compartment, hood, grille, headlamps & fender) accomplishments:

Revised hood torque rods and brackets to reduce opening/closing efforts for future vehicle best practices.

Created a proto UG-NX design file/drawing of “Hat Shape” bracket j-clip nut to attach fender onto suspension frame.

Coordinated with Mahindra Eng. India for packaging air cleaner, w-house splash shields and coil hood springs.

GM Vehicle Engineering Center, relocated from Flint, MI to Pontiac, MI. to Warren, MI.

November 1995 – October 2009

Lead Product Design Engineer for Cadillac Deville Closure/Window Sealing Systems accomplishments:

Saved $125M from stamped/attached lace to two separate integral moldings with co-extruded PVC lace / PVC belt seal-strip

oSwitched molding module from chrome stamping and separate channels/lace/belt seal to PVC co-extruded & stainless steel rolled formed molding with 2dB less wind-noise and less exposed rubber.

oAchieved early styling agreement for molding module “Jewel Appearance” (URM to OBM molding miter joint, molding to mirror/appliqué) to exceed JD Power exterior fit target by 15pts.

Eliminated body color “skunk-strip” between door interior garnish molding to primary seal that attaches to window seal carrier with (2) lower push pin fasteners and joint line relocated below belt line as and overlap joint.

Modernized dual-carrier window seal that attached to door weld flange and trim plastic garnish molding with 2dB wind-noise reduction and 4 plant assembly operators eliminated with integral garnish molding and improved quality / less build variation.

Achieved “Best in Class Target” for 26dB wind-noise & 7ft/lbs door closing efforts per benchmarked luxury brand target.

Design Product Engineer for Moldings, Weather-strips, Window Guidance/Mirror/Lock Systems, Water Deflectors, Doors

Over 5 years in Window - Guidance Group (Full, Mid. and Compact Size Truck) accomplishments:

Implemented T360 FD Wdo regulator electronic module (Saved $4M/2lbs) through size reductions to motor, rails & clamps:

oEliminated $1M wind-noise and window adjustment warranty with window changes.

oLaunched and completed Magna’s lab testing through regulator/weather-strip/window changes.

Directed (GMM Eng. / Delphi / Packard) T610 FD Wdo Reg-Handle-Lk Electronic Module with new side airbag /BCM wire-harness dock/lock connector. Developed revisions from build events/testing/quotes from GMM Design & Packard.

Pull-Ahead new Technology, which saved $140M with upgrades from T800 lift-glass (integral encapsulated appliqué, handle, h/ware) to T800/900 (bonded h/ware, electronic defrost, mechanical attach appliqué/handle):

oManaged rear-end fit and finish harmony with enhanced flush/gap glass appearance.

oPassed solar test on Chevy/GMC roof appliqué mechanical attachment with common Cadillac attachment method.

Reduced T800 FD trim install efforts 70 lbs. with Polyethylene water deflector pockets/trim hook changes, which reduced install time by 10 seconds at 7 plants. Our Team Project awarded the “People Make Quality Happen Award” by GM Eng. VP.

Avoided $30M in-warranty repairs by resolving T800 door water leaks from 10 to 0% at 7 GM Assembly Plants with new Polypropylene bottom deflectors. Awarded “In Pursuit of GM Excellence” from GM Engineering Director.

GM BOC- Detroit Automotive Division E/K Cadillac Platform relocated from Troy, MI. to Flint, MI.

November 1989 – November 1995

Design Product Engineer for 92 Cad. Eldorado Body Closures (Window Moldings & Sealing System) accomplishments:

Recipient of lean mfg. contractor “Guru” Sandy Munro workshop to improve sealing/window adjust asm. process:

Implemented a combined upper reveal molding/w-strip retainer with new rivet attachments for new blow-out clip.

Added water management features to front/rear muckets along A/B-Pillars & (2) form beads along btm. of door.

Supported window micro adjustor change from in/out to up/down as the new Key Product Characteristic.

Serviceable trim bezel/electric switches (power locks-window-mirror-tweeter) & “shark-fin” removable trim to service mirror.

Design Product Engineer for 91 Buick Reatta Hardtop/Convertible Body Closure/Window Sealing Systems [DIW, hardware (hinges, inside/outside mirrors & handles), window/mirror/lock power electronic regulator module. Interfacing with door/garnish trim, general assembly, Clark Street CMM Room, and Body Shop CMM Room] accomplishments:

Optimized door inner panel “twist”/door hanging per CMM data/clay seal margins checks to improve closing efforts.

Shifted door trim pad door inner panel hole pattern forward for extra clearance to qtr. trim, which reduced closing efforts.

GM BOC-Flint Automotive Division for C/H Buick Platform, Troy, MI.

July 1985 – November 1989

Design Product Engineer for BIW (Motor/Floor/Rear Compartment, Rocker Outer, LeSabre/Delta-88 Exterior Lighting) accomplishments:

Changed rocker reinforcement from stampings to a constant rolled formed section with multiple punched hole patterns to attach the various plastic rocker sill plate trims for a $3 cost reduction and improved structure.

Deleted bathtub spare tire reinforcement for a 3.5 lbs. mass reduction, spot weld reductions and $6-piece cost reduction validated by drop silo testing and rear end crash testing coordinated with new plastic gas tank & new hat shape bracket.

Achieved the following accomplishments on the 1990 new rear end styling enhancement with studio Class-A surface for the Buick-LeSabre/Olds-Delta 88 for exterior lighting (GM Guide Lamp) and SMC finishing panels (GE Plastics & Premix):

oObtained GM-styling design agreement with studio surface for exterior lighting, finishing panels, quarter panels and metal rear end panel form changes per a rear end hardware styling buck.

oAdded die form and pierce hole changes into rear end and quarter panels for the new tail lamps/finishing panels, which were successfully prototyped/mocked-up and pulled ahead into current production.

EDUCATION: Bachelor of Science in Mechanical Engineering from WMU, Kalamazoo, Mi (Engineering Thesis: CAD-DRAM Analysis of a Prab Robot, which was published in a 1984 SME journal)

Key Words: SAE, SME, ASBE, action driven, analytical, authorized, committed, competent, consolidated, crafted, cost effective, determined, driven, dynamic, earned, empowered, energized, focused, honored, introduced, invented, launched, multi-task, market driven, negotiated, promoted, persistent, pioneer, proactive, practical, restructured, results driven, self-motivated, targeted, transformed, tenacious, upgraded and verified, Technology, Project Risk, GD&T stack-up analysis, Microsoft Office, Microsoft X-Cell, Microsoft Power Point, Microsoft Word, Mechanical Engineering, Auto Cad, FEA (Finite Element Analysis), Pre Production, Launch Experience, Tooling Design, BOM (Bill of Material), RFQ (Request for Quote), BIW (Body in White), Release Engineer, BIW (Body in White), BSME (Bachelors of Science in Mechanical Engineering), Attention to Detail, Wind tunnel testing.

Contact this candidate