Athear Salem

**** ******** **

Walled Lake, MI **390

adem8n@r.postjobfree.com 248-***-****

Sr. Product/Design Engineer

Program management

Graduate Mechanical Engineer with 25+ years of diversified Engineering, Design & Development experience in the automotive industries.

Extensive background in Product Design and Development, Expertise includes seating systems, mechanism & components and structures, structural plastics, stamping, die-casting, Instrument Clusters, Body-In-White, interior & exterior trims, power train & engine components, molds, tools, dies & fixtures design. Including exhaust system design (DOC, DPF, SCR, & UREA).

Proficient working with studio Class-A surfacing, 3D Solids, Mold-flow Analysis, Sheet metal Forming Simulation, Structural, Linear, Stress & Thermal Analysis using FEA principals.

Knowledgeable in GD&T (ASME Y14.5M 1994) and Tolerance & dimensional stack-ups, DFMEA, DVP&R, DFSS Processes., PFMEA, TRIZ, & ARIZ.

In-depth knowledge of testing practices, manufacturing procedures, plant operations, machine capabilities and mass production requirements.

Extensive knowledge of Major CAD software (e.g. Unigraphics NX, CATIA V5, Pro-Engineer, Wildfire and Creo.

Technical Expertise

CATIA V5

Unigraphics NX

Pro-Engineer

Team Center

Vis Mockup, VPM, TDM

Finite Element Analysis(FEA)

Plastics design release

Sheet metal, Die-casting

Component design

Microsoft Office Suite

Injection molding.

Vac forming

2 shot molding

extrusion processes

Exhaust Systems

Seating System(seat complete)

Instrument Clusters

Body-in-White

Interior & Exterior Trims, Roof Rack Systems

Mold Flow Analysis

Tolerance Stack-up

GD&T (ASME Y14.5M-1994)

DFSS, DFMEA, DVP&R, PFMEA, TRIZ, ARIZ

WERS/AVBOM/FEEDE BOM Release System

E SQUARED, PRTS

Lean Manufacturing, 8D

Program Management, MSU text book training 2008-2011

Professional Highlights

1.ADIENT-PLYMOUTH

Product Engineer (Seat Complete) 2/2020-5-2020

Worked on seat complete from concept to production.

Design release engineer for several programs for North America.

2.FORD — Dearborn, MI

Product Engineer (IP and Console, HVAC Ducts) 5/2019-7-2019

Worked on BOM for electric vehicle for china market for 2021. Design and Release for HVAC DUCTS for new truck platform.

3.FIAT CHRYSLER AUTOMOTIVE, AUBRUN HILLS, MI

Lead Exterior Body Engineer 11/2018, 4/2019 (Project)

Lead Engineering and acted as Program Manager for Wagoneer Roof Rack.

New design and development for FCA.

Utilized all the FCA release systems to release plastic injection molded the roof rack, including team center, NX CAD. Modified CAD as needed to clean up files.

4.FORD — Dearborn, MI

Sr. Lead Engineer and Program Manager, 3/2016-11/2018

Working on cost reduction (TVM) for soft trim components, plastic parts for all North American programs.

Designed, developed, tested, ran plant trials, got management and PVT approvals and implemented and booked savings. Exceeded cost targets for the 2015, 2016, 2017 & 2018. Was recognized by the chief engineer for exceeding targets. Also recognized by supervisor for saving 2.4 million on one change.

Supervised lower level employees with less experience.

Sr. Lead Engineer Ford Edge, NA, C.EU.CD390, & X. 6 Programs total. 3/2013-3/2016

Worked on soft trim components from concept to production for design and development Responsibilities. Program management for several programs in beginning for cost, tooling and requirements.

Utilizing CAD, CATIA V5, Vis Mockup, and Team Center for developing components and assemblies from cradle to grave. Mods parts were Ford designed by me and other the supplier designed the parts.

Worked from concept to production and all the documentation to go along with every part. I have about 25 parts per vehicle. Supported the supplier on Tooling design and process.

5.NAVISTAR— Lisle, IL 3/2011-3/2013

Sr. Lead Engineer / Program Manager Truck

Lead the engineering team for the development of the complete Cab for all truck. Worked with NX and team center to develop parts for the Cab. Truck includes light, school bus, medium & heavy duty trucks for International trucks. Designed & Developed Air-ride suspension, seat & cushion adjusters, back frame & cushion structures for school bus.

Responsibilities include for complete program accountability in terms of product performance, cost and timing (program management). Interaction with customers, manufacturing plants and suppliers.

Managing open issues, Co-ordination with design teams in India & FEA groups. Involved in developing DFMEA, DVP&R documentations.

Conducted Design Reviews, VA/VE activities, Build samples & coordinate testing.

Became program manager for the new mini build site in IN. Responsible to acquire all part to build a truck

Program Management, MSU text book training 2008-2011

6.TENNECO AUTOMOTIVE, Grass Lake, MI 1/2008-11/2008

Sr. Design Engineer / Program Manager

Designed & developed complete canned exhaust systems for CAT and John Deer.

Developed a new wrapping insulation system to work in the plant cell. New continuous wrapping method.

Used Catia V5 to design shop tool for assembling the bricks, DOC, DPF. Modeled parts and made prints and the tools were manufactured

7.GENERAL MOTORS, WARREN, MI 12/2005-1/2008

IP/Cockpit Engineer IP and Floor Console

Designed & developed IP and Floor console for vehicle refresh.

Modified pats for cost reduction.

8.SIKA CORPORATION Madison Heights, MI — 3/2003-12/2005

Design Engineer, Baffle and Sealing

Designed baffles for sealing body cavities

Mocked up parts in the shop, bent cavities and ran test in house to validate pats before customer got them. GM was the customer. Involved in design review, tooling review, manufacturing review. Concept to production.

Also did the GM documentation at GM.

Actively involved in DFSS, DFMEA, DVP&R, Tolerance stack-up studies, Pugh analysis, system and product verification & validation, competitive product benchmarking, pilot build & launch.

Most of the parts were plastic, but some of the carriers were metal stamping. 2 shot molding process. Plastic and expandable sealer.

9.FORD — Dearborn, MI 3/2002-3/2003

Value Engineer, Seating cost reduction (MCR)

Worked on cost reduction for all SUV and cars for Ford North America. Met all the targets for 2001.

Worked on cost reduction for seating and soft trim components.

10.EDAG — TROY, MI 3/2000-12/2001

Design Release Engineer for Seating Engineer, Acoustic Engineer

Worked on Hummer 2 vehicle. Designed seats for the whole vehicle. First, second, third row seat were design with different foam and trim.

Validated the seating for all FMVSS. Front row seat had all belts to seats. Validation consisted one crashed vehicle and several sleds.

Worked at the GM troy tech center. Also supported all the built vehicles at the validation center. Singed off all vehicle after the prototype build was complete.

Designed the soft trim for the whole vehicle.

Was part of team to select source suppliers for seats and soft trim? Once suppliers were sourced, I took the role of program manager

As program manger the responsibility was cost, tooling, and requirements. Also reporting to management.

11.COLLINS AND AIKMAN — 8/1997-3/2000

Design Engineer, Acoustic Products Engineer

Worked on VN127 the 2 door minivan soft trim complete package. Sometimes co located at Ford.

Worked concept to production on all the parts. Worked with different suppliers for complete acoustic package.

Worked the complete launch at Oakville Assembly Plant.

Also launched the F250 super duty at KTP

12.YAZAKI NORTH AMERICA — Canton, MI 5/1995-8/1997

Design Engineer, Wiring and Shields

Designed plastic parts and PDB for wiring harness group. Ford components group.

Validated part on Ford vehicle. Used a 2 d and 3 D system ford design.

13.FORD, Livonia, MI, 5/1994-5/1995

Transmission, Powertrain Development Engineer

OBDII Catalyst Monitor. Development Engineer for powertrain group

Ran several test on vehicle normal operating temperatures, and normal gas engine operation conditions.

Worked with the full engine powertrain and transmission for driving on tracked dynon-mometeror.

Academic Qualifications

BSME, Mechanical Engineering June 1994

Wayne State University

Specialized Training

DFSS, DFMEA, DVP&R, PFMEA, TRIZ, ARIZ

Unigraphics NX (Modelling)

Catia V5 (Part Design, Assembly Design)

Team Center

PRO E Wildfire

WERS/AVBOM/FEEDE BOM Release System

E SQUARED, PRTS+, VIS Mockup

DVP&R, DFMEA, PFMEA

Lean Manufacturing, 8D

Program Management, MSU text book training 2008-2011

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