John Sparhawk

616-***-****

adycq8@r.postjobfree.com

Career Profile

Seasoned engineer with years of product safety experience and experience in implementing design solutions for companies ranging in size from a small family owned solar company to Fortune 500 companies. Conceptualized and managed the development of many components including Seating systems(JIT), head restraints, electromechanical, plastic interior trim, mechanisms, seating, sensors, sheet metal, and full vehicle crash. These projects were funded for $20K to $1 billion (new truck). Led team sizes of 5 to 20 people.

Core competencies include: Product Development, DFMEA, DVP&R, Drawing Release, Project Design, Project Management, Team Management, Forecasting, Project Tracking, Financial Management, Expense Management, Quality Assurance Testing, Statistical Process Control (SPC), Root Cause Analysis, Advanced Quality Planning, Testing to failure, Kepner-trego, etcetera.

Some software used include: Delta CAD, Catia for engineers, Word, Excel, MiniTab, Powerpoint, Outlook, VAX, WERS.

Career Highlights

Patent Award on seat belt locking electromechanical device resulting in increased market penetration into Mercedes Benz and General Motors. Patent #5538098

Cost reduction efforts paid off with over $2.00 per Mustang seat. No cost reductions ever identified in +10 yrs.

Implemented foot clamps reduced line time by 60 seconds and ensured customer satisfaction at the Michigan Ford Plant.

Ford Motor Company, Flat Rock Assembly Plant, Flat Rock, MI 03/2023-06/2023

Product Development Engineer PVT – Short Term Contract – Reference Available

-Review incoming warranty claims data on a daily basis, review customer and dealership comments, bin claims into proper categories, contact dealerships for parts and repair diagnoses, participate in customer call back to ensure proper understanding of customer inputs in Quality surveys, review returned parts for root cause analysis and develop Interim Containment and Permanent Corrective Actions. Supporting assembly plant with Stop Ships/Stop Builds, Campaigns, Audits, Root Cause Analysis and other Quality issues. Maintain sub-system or Vehicle Functional Group (VFG) level Quality documents and drive the achievement of quality targets. Lead engineering design changes for future minor product launches. Support Variability Reduction Team (VRT) for specific sub-systems and work closely with Supplier partners for sub-system components to address quality concerns Lead engineering trials and the implementation of running changes for the sub-system Issue engineering Alerts and initiate & pursue authorization of engineering Concerns for product changes to support Quality objectives Engage technical experts and functional team members for driving resolution and in developing corrective actions to improve product Quality

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The Solar RAQ- Pontiac, MI 12/2014 – 3/2023

Project Engineer

This is a multiple hat in plant position. Design and release of structures to mount solar panels. Ensuring incoming components are to print and are of high quality. Developed SOR for writing Lean Manufacturing instructions for the assembly of the structure. Leading projects from inception to completion. Diagnose problems and implement solutions. Trained technicians on assembly proess. Evaluating Process Improvements, Preparing quotes. Powder coat and furnace booth design. Customer relations and communication of budgets and timelines. Validation of structural components. Interfacing with suppliers and cross-functional teams. Mechanical design of 1 MW project in Eau Clair Wisconsin. Residential Battery Backup solutions. Reduced solar panel installation time by 70%. Selection of electrical components. Responsible for DFMEA, DVP&R, DFM, BOM and GD&T.

Charlton Group, Saint Clair Shores, MI 10/2012 – 12/2014

Engineering Program Manager

Represented a Chinese company in all aspects of program with GM on daily basis at the VEC. Drove open Issues to closure with multi-functional team members. Commodity: Plastic wood grain injection molded trim, LED lighting.

Johnson Controls/Bridgewater Detroit MI - Contract 02/2009-10/2012

Project Engineer

Responsible for the seat heat and vent electromechanical system and with sub-products: Steel seat and plastic injection molded trim, sensors, dc motors, and mechanisms. Responsible for the design and release of stamped metals, mechanisms, plastics, rubber, foam, trim, electronics, and regulatory compliance/validation of the complete seat. D/PFMEA, DVP&R, DFM, BOM Drove quality improvements by implementing automated foot clamps for placing sensor. Wrote lean manufacturing work instructions and containment procedures using Six Sigma concepts.

Ford Motor, Dearborn, MI 01/2006 -10/2008

Complete Seat Product Engineer

Led cross functional teams in world class seat design and center console. Tracked BOM including cost and weight BOM. Drove open issues to closure using team approach. Drove quality resolutions with supplies, wrote lean assembly instruction, and trained personal on assembly of seating system. IIHS head restraints sled testing and design modifications. Interacted with cross functional team to make Quality Job 1. 8D, 5 whys, root cause analysis. Sled Testing of Seat backs/head restraints for neck injury improvement.

LEAR, Southfield, MI 03/2002-01/2006

Complete Seat Engineer

Primary: Design and release of complete seat systems. Sub-Components: plastics, structure, foam, trim, latches, OCS, wire harness, heater elements, strikers, and fasteners. Supervision of two engineers. Led cross-functional team of seven engineers. Customer interface with Ford Motor, Mazda Motor, and Hyundai Motor. Spent 8 months on plant floor during launch. Cost reduction efforts paid off with over

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$2.00 per seat. Open issues, DFMEA, DVP&R, SOR design review, fit and finish reviews, comfort reviews. Design for Six Sigma certification.

Received an innovation award from Lear for efforts on plastic injection molded seat structure design.

FISHER DYNAMICS, St. Clair Shores, MI 06/2001-03/2002

Lead Engineer

Design and release of automotive seating mechanisms. Processes included, stamping, forging, broaching, fine blanking, progressive dies, powdered metals, heat treating. Mechanism was too costly per OEM direction, proposed that the cams be produced from powered metal. This resulted in a $0.25 cost saving per mechanism.

DAIMLER CHRYSLER, Detroit, MI 01/1995-03/2001

Product Engineer – Seating Systems

Responsible for the system level DFMEA, BOM, DVP&R,

Dodge Truck -Components: Buckle Assy. wiring harnesses, switches, steering column, plastic shroud and intermediate shaft.

Achieved a cost reduction by reducing complexity of buckle assembly.

Compliance of Dodge Truck platform to foreign and domestic MVSS full vehicle test requirements (201, 207/210, 208, 209, 212, 214, 219, and 301).

Managed programs timing and budget through various product development stages

Led top-level Safety Umbrella presentations. Represented department at all Corporate Safety meetings.

Utilized innovative air bag, seat belt designs and energy management designs.

Achieved a successful product launch and a five star / five star safety rating for the Small Truck Platform.

Automotive Industry Action Group team member

TRW VSSI, Washington, MI

Project Engineer 01/1992-02/1995

Components: Air bags, seat belts, wiring harnesses, sensor systems, motorized seat belt tracks and seat integrated restraints, T16949 – Continuous Improvement Training, Contributed to early smart restraint development. Received an innovation award for a patent on normally locked without power electric seatbelt retractor.

EDUCATION

Bachelor of Science

Engineering (mech. & elec. classes) Lawrence Technological University, Southfield, MI

Master of Business Administration Lawrence Technological University, Southfield, MI

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