Design Engineer Engineering

CHARLES D. BROWN

*** ********* **. *****: 1-586-***-****

McDonough, GA 30252 ********.*****@*****.***

CAREER SUMMARY

Project Lead, Design Engineer with over 20 years of increasingly responsible experience with multiple major automotive and heavy-duty truck & bus manufactures. I have proven my leadership capabilities by applying a strategic approach to overall system level cost reduction without compromising design and function. I managed a strong track record in on time, on budget with impeccable delivery of design to production. One of my key traits is effectively developing professional relationships and maintaining communication on all levels.

PROFESSIONAL EXPERIENCE

BLUE BIRD BUS CORPORATION

Macon, Georgia. Leading manufacturer of school buses and commercial buses

Project Lead, Design Engineer lV, Bus and Body division September 2011 to Present

Lead design responsibility for Installing 180 ROSCO camera system as standard safety equipment to be included on C and D Class buses. This design provides two cameras’ that will be installed in production on over 12,000 buses, one located on rear roof cap of bus and the other located at center of hood grille. Both cameras will be calibrated for a 180-degree field of vision. The rear and front cameras are displayed via a built-in monitor through the surface of the driver’s interior rearview mirror that’s mounted on the overhead structure. This feature will meet the Abigail’s Law requirements in New Jersey. Abigail’s Law requires that driver will be able to see in front of the school bus when service door is opened and monitor will remain active for ten seconds after service doors are closed.

Integrated Bendix Wingman Advanced with active braking system as standard safety equipment in BBCV conventional buses. With the use of three modules, DIU (Driver Interface Unit) and IP cable routing the Bendix Wingman Advanced brings together adaptive cruise control with braking features along with collision mitigation technology.

Flawless delivery of Bergstrom auxiliary pumps for interior coolant heating systems on all bus models to gain additional GPM while on track to save an estimated $300,000 annually with supplier resourcing.

Responsibility for fast-track delivery of both bonded type and Transit TSW window Business Project (BP) releases. New window frame design improved window installation time per bus for efficiency. Also, to improve quality I began by taking a leading stance on getting perfect results in DVP&R testing by eliminating problematic leaks in windows. Stayed on track with meeting target dates for implementation of new TSW windows by mid-2019 with estimated savings of $250,000 annually.

Designed above floor solution for heater plumbing routing system across S.E.D (Side Emergency Door) that reduces cost in labor with material savings at an estimated in-total $200,000 since 2015.

Improved entire plywood flooring installation process to help reduce material cost while improving efficiency by designing 1200 new kitted parts unique to each body model.

Worked with supplier Safe Fleet to successfully deliver improved bumper crossing arm design on BBCV and T3 products on a 3-month timeline to production.

Redesigned toolbox and Webasto heater system compartment for improved appearance by adding frame with communized keyed latches. Estimated $30,000 in-total savings since 2013 implementation.

NAVISTAR INTERNATIONAL CORPORATION

Fort Wayne, Indiana. Manufacturer of medium and heavy trucks & engines

Design Engineer lll, Cab in White (CIW) and Exteriors February 2009 to August 2011

Design engineering lead with responsibility for design and release of steel bumper with integrated fascia for CAT SS C64, C67 & C70 while working with Roush designers. Also, developed detailed business case for a system-level dual remote hood latch with cab interior access for CAT SS program similar to Volvo VNL Series truck.

Design release of FMVSS & CMVSS approved AWD C70 bumper with headlights.

Designer for hood reinforcement brackets, splash panels and hood insulation foam for severe duty truck applications.

Development of cost reduction concept sheets for HD2 – Aluminum and HPV- Steel cab sealing.

Organized documentation of all production material property specifications called MPS documents.

Managed weekly communication meetings with CAD designers located in Fort Wayne, IN regarding design changes that derived from Pyxis concerns on newly released exterior parts at Garland, Texas Assembly Plant.

FORD MOTOR COMPANY

Dearborn, Michigan. Manufacturer of automobiles and Mid-size trucks

Design Release Engineer, Front and Rear Fascia Bumpers November 2006 to January 2009

Using my previous BIW launch experience I supported all Frt & Rear end production efforts starting from Ford Milestone TT, MP1 and MP2 to final production stages for the 2009 Ford Flex front & rear fascia and steel impact beam system.

Actively participated as a member of various Value Stream Teams to drive resolution of common cause and special cause issues that negatively impact Plant Reliability.

Participated in 8-D Phred meetings to outline and solve current production issues effectively.

Reduced costly operator redundancy by improving lamp catcher bracket teeth to help fascia engagement efforts at fascia install operation.

Designed and developed fiberglass reinforcement grille to improve airflow efforts.

Eliminated class a surface wavy concerns by improving all attachments to new fiberglass shelf on reinforcement grille.

Using Plant on-site applications like Team center, Unigraphics, design team and CAE I performed numerous impact & air bag censor test simulations on high-strength steel beam designs.

Assist in developing/maintaining engineering best practices and product standards.

Upgraded engineering drawings with latest ASTM’s physical and mechanical testing standards for supplier resourcing.

GENERAL MOTORS CORPORATION, Warren, Michigan

World’s leading manufacture of automobiles and trucks

Design Engineer, Frt & RR Sheet metal and Fascia Appliqué June 1996 to April 2006

Established new manufacturing practices to control smaller gaps between interfaces components, such as; Hood to Fascia, Fender to Hood & Fascia, Fascia grille and Frt & RR Lamps alignments.

Achieved second highest performance-to-target award for over $400,000 in cost savings on Saab License Plate Pocket by communizing seal profile. Once seal is implemented to other mid-size truck platforms, cost savings could potentially reach over $1000, 000.00

Successfully designed and executed new Frt Fascia bumper, Hood-outer, Hood-inner, and LH & RH Fenders with the use of aluminum metals for SAAB next generation SUV.

Design new hood release latch module assembly using “off the shelf” communized handle and metallic steels for springs to meet new front-end mass requirements.

Developed radiator support steel beam supported with 12 new lightweight metallic rivets.

Facilitated weekly PDT meetings, design reviews and management reviews ensuring fast

Resolution to list of issues: Fascia attachment, Hood ornamentation and Fascia w/ Grille Shrinkage.

Partnered with the Design Studio to ensure a timely release of new design data for each component.

Led front-end reviews at the CIT to help resolve design conflicts quickly and effectively.

Worked cross-functionally, as an active member of the Cost Reduction Execution Team with current production engineering teams to gain support for material cost reduction recommendations.

Supervisor responsibility for 20-person production line of assembly operators, line mechanics and electricians to interpret work orders, GD&T drawings, parts lists, releases and program schedules to ensure timely material procurement for sister plants.

Responsible for implementing total reliability and quality launch process document standards.

Supported release engineers by resolving operator issues and performing pilot test for results.

Plant site engineering support to help resolved engineering design issues, through use of CAD systems.

EDUCATION/ TRAINING

Central Michigan University, Mount Pleasant, MI

MSA in Engineering Management 2003

BS in Mechanical Engineering; Major in Product Design 2001

DFSS Greenbelt certified, APQP, DFMEA, DFM/A, DVP&R, 8-D, PPAP, Proficient in NX6, Catia V5, AutoCAD 3D, SolidWorks,

Pro-E, Creo, aPriori, IMAN, Team center, digital buck, Pyxis Tracking Systems, PRTS Systems, PLM, Smart Team, E Squared, CDMS, WERS, Lotus Notes, Phred, Excel and Word.

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