Fadi Zara

US Mobile: 202-***-****

Email: adkisu@r.postjobfree.com

SUMMARY

Over 25 years of experience in automotive NVH powertrain, chassis, and vehicle development. The last 7 years focused more on Chassis tuning, vehicle dynamic, and NVH Vehicle development, NVH post durability design and validation

EDUCATION

The George Washington University, Washington DC, December 2001

Master of Science - Engineering Management and Electromechanical Engineering – GPA 3.8

University of Phoenix May 1999

Bachelor of Science in Computer Information Systems – GPA 3.5

Macomb Community College, Warren, MI, May 1994

Associate Degree in Applied Science Automotive Technology

AWARDS:

Received highest honorary credential award employee of the year of 2019 from the Chairman of FAW Group

Received honorary credential award for good technical advice from the Chairman of FAW Group 2020

CERTIFICATIONS & TRAINING

Principles of Acoustics, Bruel & Kjaer 1998

Principles of Vibration, Bruel & Kjaer 1998

Spectrum Analysis of Sound and Vibration, Bruel & Kjaer 1999

Black belt Certified by American Axle and Manufacturing 2003

DisCom Software training for production EOL

Head Acoustics Artimis 2004

Master Black Belt Training from Unisys Corporation 2006

LEAP Leadership Excellence Acceleration Program 2005 (Unisys Corp) 2006

Completed PMP training from the PMI institute 2005

RLDA WFT training by Michigan Scientific Corporation 2004

B&K PULSE v16 2012

K&C training by Morris Dynamics in NC USA

MSC Linear Static Analysis using Nastran & Patran (NAS120)

nCode GlyphWorks, and DesignLife 2012

Head Acoustics Artimis Suite 2015

FAW Car Company Bestune Car Company March 2019-Present

Director of vehicle NVH development

Own the complete responsibility of meeting complete vehicle NVH attributes and working on meeting overall vehicle NVH targets

Support our vehicle and powertrain quality to setup NVH targets to EOL monitoring system to meet the product consistency targets

Developed and deployed a system to monitor overall vehicle NVH performance for the manufacturing team that is being used daily.

Create a VTS document for complete vehicle and focus on the dynamic and NVH attribute targets.

Conduct chassis tunning to meet the ride, handling, and road noise and vibration target requirements.

Provide chassis, powertrain, and complete vehicle NVH & BSR problem solving assistance to the manufacturing and quality department

Work with the E-motor development team to provide NVH design guidelines to meet the NVH target requirements

Interact with multifunctional teams to resolve vehicle and component NVH issues

Conduct TPA analysis to solve complex vehicle, powertrain, EV motor, and gear box issues and propose an engineering solution that satisfy engineer and manufacturing for mass production

Conduct benchmark analysis and create a target attributes system to meet vehicle dynamic and NVH

Create NVH structural stiffness targets for local and global modes of BIW and closures to meet vehicle dynamic and NVH performance target

Provide NVH powertrain targets for critical components that have major NVH contribution to the suppliers

Provide CAE design guidelines to the CAE team to meet the structural stiffness CAE targets

Conduct ESP NVH assessment to make sure that ACC meets the target dynamic and NVH requirements

Create clear NVH testing plans that meets NVH reliability and durability targets

Created a systematic approach on creating NVH targets for new vehicles and post durability of 3 dB degradation post 240 KM’s

Created a complete vehicle dynamic and NVH systematic design approach and validation procedures for the company and conduct at least 6 training classes per quarter

Manage a team of 21 NVH engineers. Provide them technical directions and hands-on training

Karma Automotive & Canoo, Los Angles California September 2017– March 2019

Sr. Manager Vehicle Development

Manage a team of 12 engineers in Vehicle integration NVH department

Provided CAE BIW stiffness targets to the design team to meet the overall vehicle NVH and dynamic target

Manage all NVH testing activities for powertrain, driveline, BSR, and overall vehicle integration

Conduct multiple RLDA testing in the vehicle in a proving ground and predict critical data to the MBD to conduct virtual analysis to predict the proper bushing rates by using ADAMS

Resolved critical e-motor/RDM noise issue that was a major concern for the company

Responsible for vehicle system and sub-components NVH target settings

Work very closely with the CAE team to make sure the analytical NVH simulation correlates with testing results

Responsible to create a durability schedule for Karma key characteristic components.

Setup NVH targets by conducting benchmark analysis and identify Key Critical Attributes (KCA)

Work very closely with the Inverter and motor team to make sure the NVH target set during the design phase, build NVH testing plan, then execute the plan

Conduct chassis tuning a for multiple vehicle programs by working hand in hand the spring, damper, and bushing suppliers to meet the target

Develop a methodology for aeroacoustics /CFD testing working with the thermal dynamic team to make sure the cooling requirement met the sound target as well met from an aeroacoustics point view.

Develop NVH testing plan for powertrain and driveline mount tuning to establish the proper vibration isolation from gear whine and eliminate tip-in/tip-out noise and clunk noise.

Great standard operating procedures for vehicle NVH testing, bench, and TPA testing

Work with our high voltage battery supplier to set NVH targets for the battery contactors under WOT.

Support production manufacturing plants with all NVH related noise issues and setup NVH EOL targets for component, subcomponent, and vehicle system

Great Wall Motor Limited, Baoding, China September 2015 – September 2017

Chief Engineer of System Development Department (NVH/CAE)

Own the responsibility of the overall system development department which have three sections NVH, CAE, and system integration

Manage total of 70 NVH/CAE and testing personnel in GWM driveline division

Responsible of hiring staff for the department

Lead the NVH/CAE and the system integration of the 48Vdc and HVdc Inverters for Hybrid vehicles.

Manage all winter, summer, and altitude tests for the TM development

Educate the department team members of CAE and NVH techniques; such problem solving, design phase optimization virtual analysis, NVH testing…etc.

Create durability testing plan and activities to validate design and validate PT build transmissions, RDU, PTU and 48v e-axle and complete hybrid system

Mange the planning and activities with vehicle engine team to manage the powertrain system. Conduct meeting with Schaeffler, Bosh to make sure we have the right transmission configurations for the engine

Coordinate all workshops between company inter departments and contractors to establish hands-on test drives and calibration in a controlled testing environment

Order the hardware and software required for the testing programs

Responsible of the management of the durability vehicles issue when it comes to NVH and calibration related issue. (NVH related to calibration)

Prepare weekly and monthly report to the executive management that provides program status and planned activities for the system development department.

Interdicted analysis methodology to GWM to resolve torsional vibration issues that created a new analysis and testing capabilities for GWM

Manage the implementation of the EOL function test with manufacturing team and responsible of establishing the EOL NVH limits of gear whine, mechanical pump noise, shift noise, and teach-in of the TCU that’s correlated to the vehicle quality expectations

Manage the coordinate the entire cold chamber testing activities with the R&D center to conduct dither testing that’s coordinated with the hydraulics department

Conduct daily vehicle drive and communicate the results to the calibration team leaders. Based on the results the priority of tasks can be shifted.

Established systematic techniques for benchmark analysis of driveline system such hybrid system e-axle, BSG, which had a high successful rate of exceeding the performance component level.

McLaren Performance Technology., Livonia, MI November 2013 – September-2015

Engineering Manager – Vehicle & Powertrain Development

Responsible of the NVH department that support product developed, and Plant support with all NVH related aspects of RDU’s, PTU’s, engine testing, and transmissions

Manage 12 NVH engineers and 4 gear development engineers in the department

Developed "NVH Driveline Product Development Process" to be applied to new programs covering all NVH testing, analysis, refinement and key gateway reports from kickoff through production to PPAP sign-off.

Manage NVH attribute development for driveline products with program target setting through milestones to resolving issues and delivering high quality Power Transfer Units (PTU) & Rear Drive Units (RDU) products.

Trained, mentored and led two new NVH engineers and provided transitional program support for a five-month ram-up period enabling engineers to learn order tracking, rotational machinery and driveline analysis.

Managed the 2016 Camaro/Cadillac (RDU) program from kickoff to PV. Developed and conducted all NVH related activities including root cause and design optimization for NVH. Utilized DFMEA, DVP&R, FRF, modal, vehicle and dynamometer testing, preload and gear quality optimization.

Managed the 2014 C7 Corvette Axle (RDU) program from phase2 prototype to production and launch at the plant. Correlation of the NVH EOL test stand to the lab dynamometer, Vehicle Subjective/Objective and development of a custom metric to catch poor hypoid patterns preventing in-vehicle harmonic noise.

Technical lead on Clutch Moan Design for Six Sigma (DFSS) project including the development of new testing methodology and dynamometer-based metric using frequency analysis to correlate to subjective evaluations.

Led Volkswagen MQB PTU/RDU platform during phase2 prototypes. Resolved prototype NVH issues and interfaced with plant including onsite resolution such as "Ghost Orders" and other gear issues utilizing hypoid single flank machines (SFT gear testers) and NVH EoL test stands.

Managed overhaul of NVH lab and dyno instrumentation maintenance, calibration, status tracking, engineering report/presentation references and database traceability to ensure ISO compliance.

Oshkosh Corporation May 2004– November 2013

Engineering Manager – NVH / CAE

Implement an NVH department supporting JLG reporting to Sr. Director of Core technology of Oshkosh

Manage total of 6 personnel, 4 NVH/FEA engineers, and 2 test technicians

Implemented eDAQ system to measure vibration, embrasure, pressure. etc. in the NVH lab and trained the department personnel the use of the hardware / software, then documented an SOP.

Educated team members of sound and vibration measurement techniques

Support New product development (NPD) of Aerial Work Platform(AWP), and Telescopic Machine Handler (TMH) with all NVH requested in the design phase, by providing input to the DFMEA

Support production by conducting lean events and at some cases support PFMEA activity to NVH conformance

Support all JLG manufacturing plants globally, plant quality, and Warranty with all NVH issue

Found the root cause of a problem for JLG AWP product that lead to $560K per year cost saving

Use statistical methods to determine root cause such as DFSS, Shainin, Hypothesis Analysis

Travel to customer sites as required to investigate sound or vibration issues using B&K data acquisition system

Support JLG powertrain department by working with the suppliers to have parts application approval.

Support JLG’s reliability analysis with NVH test data, in some cased NVH department conduct vibration fatigue reliability analysis

American Axle & Manufacturing, Inc., Detroit, MI January 2002 – May 2004

NVH Engineer

Refined and implemented VSAS Vibration signature analysis system technology at manufacturing sites throughout the corporation.

Lead and establish manufacturing process changes that insure NVH conformance in manufacturing processes.

Assist Reliability Center in vehicle ride audits, objective on-road data acquisition and general NVH data analysis.

Establish system for collection and analysis of objective vehicle and manufacturing process databases.

Establish correlation of manufacturing capability to gearset, 3rd member and axle assembly specifications

Assist quality organization in establishing critical SPC charts and NVH related KPCs and KCCs

Assist manufacturing and quality in establishing traceability of gearset, 3rd member and axle builds with respect to NVH specification.

Establish and maintain VSAS equipment process capability and throughput.

Coordinate Corporate Gear Development Center gear design specifications to manufacturing processes (cutting and lapping).

General Motors Corporation, Milford, MI July 1994 to December 2001

Product Development Engineer Chassis, Brakes/Braking System, and Powertrain

Responsible of the development, implementation, and improve NVH simulation technique on “driveline Clunk” and “driveline Shudder”

Developed NVH attributes roadmap identifying the future trends in customer expectation target for passenger’s vehicles and SUV

Developed NVH test plans for instrumentation, measurements of driveline system using various of instrumentation such as Thermal couples, IPETRONIK, pressure transducers, microphones, accelerometers…etc.

Conducted "root-cause” analysis of tire impact on spindle forces and frequency resonances of Knuckle vibrations.

Consultant for quality & product improvement for Multi-Body Simulation (MBS) model.

Devised a new approach to acoustic analysis on vehicle system level by demonstrating the effect of Spindle (Road) Forces for future SUV program. Project involved Hybrid modeling of test and analysis data by utilizing MSC/ NASTRAN, LMS/ Test Lab and LMS/ Virtual Lab.

Coordinated detailed powertrain modal characteristic (idle quality) analysis and design optimization for various engine mount configuration Rubber Vs. Hydraulic to achieve VTS level performance & to improve vehicle NVH.

Member of SAE, IEEE, and INCOSE

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