Design Engineer Engineering

Benancio J. Gonzalez

**** ********** ***** (2-48-930-****

West Bloomfield, Mi, 48322 ***.********@***.***

AUTOMOTIVE AND AEROSPACE ENGINEERING

Design; Systems, Launch; Manufacturing; Quality

Collaborative Experienced Engineer with proven Record of Leadership and Delivery utilizing acquired technical expertise in Launch, Design, Quality, Systems, Test, and Manufacturing in a Team Environment.

EXPERIENCE

Hitachi Automotive Systems June 2019 – Present

Senior Product Design Engineer- Ignition Electronics – Ignition Coil Design

• Interpret Customer Requirements, to develop DVP&R and validate to Customer Satisfaction

• Lead weekly design review with Customer Design Team on customer site.

• Work with R&D to alter Design to Achieve improved output and Packaging Design Reduction of Mass, Weight, Dimension. Lead/Conduct VAVE Study to identify cost and efficiency improvements. (2 Customers)

• Lead Technology Reviews on Customer site, including Design changes achieving customer performance improvements.

• Technical Lead on Account Management Team for all Quoting.

• Facilitate component Release for Design Change levels, Support Aftermarket product design activities as required. Provide Automotive Electrical Systems and Circuits support on various issues, including Schematic explanation.

• Lead process and traceability improvements on manufacturing line. Ensure Design integrity and process controls are successful.

• Design Team lead to develop Saber Model of Coil for further analysis. Lead Design for Tester for Product Development activities including hardware and software (Matlab Simulink) and write Software Specification.

Delphi Packard-Aptiv EEA Division Oct 2015 – May 2019 Advanced Manufacturing Engineering-Global Strategy Planning Media Module Product Line.

• Identify Major deficiency in Global Manufacturing Strategy, Deliver Solution including Re- design of Testing including Software, hardware and Process analysis to identify absolute root cause and deliver customer on requirements prior to Global failure occurred.

• Benchmark Design for Manufacturing/Design for Assembly (DFM/DFA) of Printed Circuit Board (SMT) and Final Assembly.

• Support Software Team in Integration of Nav and Media Systems in vehicle platform including in Vehicle Testing to resolve system issues with boot up procedure on customer platforms, writing shell scripts and validate new software and testing.

Lead Prototyping of early stage ADAS proposed products and Electrification 24 Volt Systems.

• Prototype First time thru Designs with Pilot Plant on site to identify failure modes and resolve including performing first time through inspection. Work with Prototype Staff in house and contract to review Solder Calculations

• Solder Pad design, Solder Stencil for proper reflow coverage including Reflow characteristics to guard against Tombstoning and other failures. Adjust Stencil Aperture openings for QFN packages and connectors to achieve proper coverage. Including reflow profile and belt speed if required

• Develop/implement Strategy to deliver SMT, Testing and Final Assembly of Media Module Product Line. Work directly with Suppliers, Aptive Validation and Systems Engineers to qualify various coatings to ensure they meet IPC standards and Perform Required Testing with Vendors to meet Adhesion and ROSE testing Standards for contaminates.

• Validate new Materials and Processes introduced in project from Initial Specification, and required Testing to Customer sign off. Interpret New Standards with Systems Engineering, utilizing including DOORs to capture documentation and time line.

• Develop PFMEA, Control Plan, PDI and other Extraordinary Launch Plans as needed. Support Systems Team to identify outside venders and Deliver Micro-strain validation Requirements as needed. Represent Manufacturing on Core Team utilizing Polarian to capture requirements as required. Work with Core Manufacturing Team on DEC Product line to improve OEE and Benchmark process steps applicable elsewhere.

• Support Global Manufacturing Issues with New product Launch and Running Changes. Work with Test Engineers to validate LabView and Alphamation applications. Work Directly on Advanced Product Development Team to ensure Robust Design and Design for Manufacturability. Coordinate and administrate over Launch Build Milestones and Testing to ensure Validation, deliver Customer PPAP. Determine and Launch New Facilities and Tooling as needed Globally to meet Customer demands. Support Aspice Process at Final Test and Validation of some Software programs GM Media and Nav. Ford Motor Co Dec 2010-October 2015

Launch Team Manager - Engineering; Vehicle Operations, Chicago Assembly

• Diagnose and redesign Software and hardware for complex Alignment Robots of front End on Vehicles

• Successfully integrate/re-Engineer Super-cooler system to meet Middle East Requirements of Police Interceptor Units

• Deep dive Launch build issues all systems Electrical, Audio, Powertrain, Wiring, programming, BIW

• Lead cycle line layout reviews with VOME, the Tooling & Facilities Engineer, the Body Launch Leader, the Product Specialists and the MP&L Leader.

• Successful Final Integration and Validation of mandated Back Up Camera System on 3 Vehicle platforms prior to implementation conduct Final Validation at End of Line.

• Ensure the Cycle Line Layout and process allocations align with the current Bill of Process. Validate product/process compatibility, Lead integration of new content and Design Change on Vehicle Platform to ensure Seamless integration. Including Super-Cooler, Engine Assembly issues Chassis Module issues, Wiring Harness validation, and Body in White (BIW) Issues working with Body Assembly.

• Lead Problem solving sessions utilizing Process Mapping, Fishbone, Cause and Effect, Histograms, Why Ladder Etc. Resolve sequencing and line allocation issues with the Staff IE's, the Production Leader, the Production Coordinator and the Product Specialists.

• Lead the Emphasis Build, validate the Allocations. Rebalance work content optimizing work allocations, Lead work station capability process at each build phase. Manage Serialization and Codification of Vehicle line for Plant, via engineering design release.

• Manage End of Line PCM Programming, Configuration Files for Vehicle Configuration and Architecture, including Error Proofing. Coordinate new component releases in Launch program to insure desired transition.

• Work with VOME and Design Teams to deliver Seamless Integration of new Systems and Components into Vehicle Platform. Represent Plant on Traceability and version control Reviews (SVN) system with Supplier for EOL Downloads.

Ford Motor Co (Returned to Ford 2007) Jan 2007 – Dec 2010 Supplier Based Launch Team Leader 6R and 6F Transmission

• Launched 100% of all priority parts without issue annually, approx 26-36 parts.

• Reduce Scrap by 15% and improve OEE by 12% average annually of core 8 assigned suppliers in supply Base including diagnosing critical issues in design for manufacturing on site.

• Launch Trans Programs and ensure suppliers meet ISO/TS and Contractual specifications for delivery of components per APQP and documentation per quality system based on contractual terms set forth. Based on Technical/Engineering insight, ensure suppliers meet APQP deliverables for Ford Motor 6R and 6F trans

(GMX23F GM Trans), for design intent with regards to operating and feature content of Transmission SDS. Utilizing Technical insight: assist suppliers in meeting PPAP/PSW required timing,

• Interpret APQP and "Way Forward" deliverables/objectives; ensure Supplier compliance of Standards and practices, including capacity verification of processes and PV/DV procedures as they relate to System Design Specification, establish program objectives-performance, quality, cost, weight, function, timing, and assumptions, per contract.

• Provide/Drive input for launch readiness of supplier products including Transmission Assy and related Sensors/Actuator/GEMS Ensure proper documentation is in place and meets customer quality operating system standards. CQDC trained and Certified in APQP. Ensure Suppliers are DDL and CMMS Compliant, Subject Matter Expert ISO 9001/ IATF 16949

ROCKWELL AUTOMATION June 2005 - Nov 2006

Senior Operations Manager Great Lakes Region USA

• Responsible for directing three Organizations: Engineering, Asset Management and Technical Training Organizations. Responsible for Profit/Loss and general management of 60 professionals including related organizational managers and their subordinates. Annual budget of $20 million. Based on Technical/Engineering needs Set Internal Policy and Contractual terms as required per customer deliverables.

• Utilizing Technical insight: Develop appropriate Business Plans, growth objectives; evaluate new business opportunities. Forecasting technical deliverables; establish program objectives-performance, quality, cost, weight, function, timing, and assumptions.

• Provide engineering input for business portion of disclosure licensing/agreements, and monitor pricing, support sales team as needed. Surpassed Annual Plan in accordance to Revenue and Utilization, surpassed margin requirements in two of three organizations. VISTEON. August 2000-June 2005

Product Line Engineering Manager (Business Planner) (August 2000-June 2005) Powertrain Electronics SBU and Asian OEM Customer Business Group.

• Develop Product Line Business Plans, growth objectives; evaluate new business opportunities, establish program objectives-performance, quality, cost, weight, function, timing, and assumptions. Track business portion of confidential/joint disclosure agreements and licensing agreements, provide business input for related contracts and monitor pricing. Maintain Cycle/Capacity plans, develop and monitor Revenue Streams. Employ product design knowledge of diagnostics, architecture and HW/SW interface constraints, to ensure cost effective strategy and value.

• Perform Advanced Design to quote and deliver next generation product of Speed Control Product (ETC), and Design of PCM/TCU (including Variable Displacement Engine, Dual Transmission Apps) with related I/O and Protocol, perform related Catia. Products/Systems: Powertrain Control Module/Transmission Control Unit (including CVT), Speed Control, Electronic Throttle Control, Chassis Systems, Lighting, Fuel Systems, Small Motor Systems:Wiper/Starter/Alternator/Fuel Pump. Ford Motor Co June 1989 – August 2000

Technology/Product Planner VTO Safety and Advanced Electronics.. (Feb. 1999-August 2000)

• First to Identify and maintain technology portfolio of proposed critical technologies for future products ten years out. Crash Avoidance Systems, long-medium-short distance detection Radar/Sonar/Laser, By Wire Technologies and Green applications. (Present Day ADAS) organize and Define Technologies and

• Perform strategic and competitive analysis of current industry for specific product lines; lead internal Competitive Benchmarking Teams and Safety Forums. Identify/unite key synergies, in and outside of organization to develop new products for markets 5-10 years out. Participated in Finance and Advanced engineering in developing budget strategies to support advanced development programs.

• Study/dev. Engine/Transmission Strategies – Hybrid, Dual Clutch, Variable Displacement Engine. Transmission calibration logic sequences, OBD I (electrical opens shorts) OBDII (freeze frames) Testing. TQCM Leader Car Platforms N.A., DI (Driver Information) Total Quality April 1997 - Feb.1999

• Reduced Cost/Complexity over $200K, in sensor product and release, improved performance warranty by 30 million dollars for Speedo/Tacho aftermarket warranty Costs. Performed Drivability Testing on Fords Test Tracks, Captured data on test track and plotted to identify behavior, trouble shoot/support vehicle launch and modify parameters at assy plant for changes. Work with Systems Engineers to Validate Systems ensure compatibility of components in system Architecture for Heavy Truck and Vehicle Platforms. Develop/Author DFMEAs and FMEAs as needed.

• Validated DFMEA/PFMEA for Altec Manufacturing of Audio Systems and Instrument Cluster Assembly

• Electronics: Senior Product Design Engineer. Current Model Design responsibility: Speedometer/Tachometer System both Mechanical and Electrical, all Gauges on Instrument Cluster, including lighting strategy.

• Supported on-site Customer/Visteon Launch of product and resolve Resident Engineering issues. Lead team and drive effort based on warranty data for improved platform performance, including internal and external suppliers.

• Identified and resolved key performance issues on vehicle platforms. Resolve arising formal issues with respect to quality, performance, warranty etc. Successfully closed out all launch related and systemic issues,

"60/90 Mandated Quick Fixes".

• Redesigned Speedometer Head and Assy. Process to Improve CPU performance in Car Platforms 32% overall DI Electronics, Improve R/1000 Performance in Car Platforms 21% overall DI Electronics.

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Manufacturing Engineer: Final Assembly 3G Alternator and Rear Housing Assembly, IAR Motor Brush Product Design Engineer. Oct. 1 994-April 1997

• Successfully programmed and maintained assembly line to assemble 106 Core Models and Service Models to Supply NA/SA and Europe without issue.

• Maintain Final Assembly Line, lead quality, maintenance, and cost reduction activities, develop/implement Preventative Maintenance Program. Launched/validated new 6G Alternator Models (PPAP) per APQP Requirements and implement new hardware and software.

• Validated/Release all new models through DV/PV per Ford Specification, including other APQP Requirements. Performed machine runoffs/Launch as required, implemented new component Feeders, determine/launch new Inkjet System, new Vision System to improve warranty and performance.

• Develop FMEAs as required, direct maintenance schedule and work with skilled trades in troubleshooting machinery.

IAR Voltage Regulator (Alternator) Product Design Engineer Sept. 1993-Oct. 1994

• Design/Launch Repackaging of Current IAR from Wave Solder to Wire Bond connection strategy. Redesigned new Passive/Active Trim procedures for new product, conduct PV/DV as needed.

• Interpret warranty data to identify and drive design, cost and performance improvements for Current Model.

• Performed Design and Release functions for: Redesigned Ground planes and Power Transistor Circuits as needed. Perform work in clean room for Semiconductor manufacturing/prototyping at Electronics plant. Performed/Developed Regulator DV/PV as needed to support changes, Developed DFMEA as needed.

• Launch First SMT Line In Ford Electronics North Penn Plant. Take over related Manufacturing Assy Line for IAR (Rear Housing Assembly).

Product Test Development Engineer - Fuel Components/Systems. Oct. 1990-Sept 1993

• Design and oversee build of developmental Test System for electric Fuel Pump and Fuel Injectors for design, durability, and performance. Currently still in use in FSEL and Europe.

• Designed signal conditioning feedback control loops as needed for UUT measurement of current, voltage, and pressures for complete sensor actuator architecture to facilitate improved redesign of Electric Fuel Pump.

• Developed calibration/software specification for operational process and maintenance/repair of Test Development System.

• Designed/launched Fuel Test Systems in Alba, Hungary, Dearborn and Ypsilanti, Mi with International Team, supported Starter Motor, for same tasks.

Supervisor Production/Maintenance Rouge Dearborn Engine June 1989 - Oct. 1990

• Lead first hourly Self -Directed work Team in production; and exceed quality and performance criteria as determined by management.

• Set Maintenance schedule, delivered launch of new systems on assembly line.

• Directed Skilled trades and production personnel to implement improvements in process, cost, and safety measures.

• Developed Preventative Maintenance Program for Cam and Crankshaft Manufacturing, supervised Production/Maintenance Teams. Manage Production CMMS System. Advanced Technology and Testing Division, Allen Group Corporation. Aerospace Development Engineer, August 1986 - June 1989

• Controls System Specialist on Jet Engine Fuel Control Systems for US Navy, US Air Force, including acquiring Security Clearance.

• Designed and calibrated hardware test system feedback PID control loops to simulate extreme performance conditions for UUT. Developed software spec and directed software validation, work with Test Pilots to determine optimum test schedules and calibration strategies for optimum performance of control system.

• Documented prints to meet Government Specifications ANSI Y14, DOD 100 Standards.

• Design and Launch Valve Body and Final Assembly Test for DCX Transmission Plant (KTP), Kokomo, In, and Bosch Fuel Test Stands for Tech Center in SC and Farmington Hills. Education:

MBA University of Detroit 2001 Detroit, MI

International Business

Exchange Prgm University of Amsterdam 2000 Amsterdam, Holland MBA Capital Markets Exchange Thesis

MSEE Wayne State Univ. 1997 Detroit, MI

Electronic and Computer Control Systems

BSEE Lawrence Technological Univ. 1989 Southfield, MI Electrical Engineering

Affiliations:

IEEE Member Senior Status. Life Member SHPE

One of Co-Founders of Young Engineers and Scientists Program, and Ford Motor Co. SHPE Chapter, Former Member of Visteon Executive Hispanic Board, Ford Motor Hispanic Network Group Member of National Society of Hispanic MBAs and Society of Hispanic Professional Engineers Represented Company in MAES, SHPE and NSHMBA National Conferences. Formerly Served on Board of Directors for Latino Family Services Detroit, MI. Corporate Training Utilized: DIADEM (NI), ASPICE Labview(NI),Alphamation Training, ISO26262 Intro to JIRA Development Tool. CQDC, SCP, OBD I&II, EMT, Taguchi, CAN, Canalyzer, Canoe, ETAS, Small Motor Design, SAP, SABER, some Catia. Unigraphics:Team Center Engineering/Manufacturing Certified, eM Planner Technomatix., Small Motor Design, EMT Safegarding, Electrical System Noise Suppression.

* Trained in Program Management - APQP, PPAP, PSW, Statistical Process Control, Global 8D, DFMEA, DVP&R, and QS-9000 (QS-9000 Internal Auditor), Analytical Warranty System (AWS), Interpreting Warranty Data for Quality Engineering. Salary Management Training. Six Sigma Green Belt Certified. WERs/CMMS/MEARS MODAPTS Certified. ASPICE Process Software Development and validation. Level 0-5

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