Mechanical Engineer Product Design

Athear Salem

**** ******** **. ****** **** *****

*******@*****.*** 248-***-****

Mechanical Engineer

Mechanical Engineer with 20+ 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).

Knowledgeable in GD&T (ASME Y14.5M 1994), 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 (CATIA V5, NX, Pro-Engineer, CREO)

TECHNICAL EXPERTISE

CATIA V5, NX

Pro-Engineer

SolidWorks

Team Center, PLM

Vis Mockup, JIRA, Ariba, AGILE, windchill, GDPNS

Plastics design release.

Sheet metal, Die-casting

Component design

Microsoft Office Suite

Injection molding.

Vac forming

2 shot molding.

extrusion processes

Seating System (seat complete),

interior lighting

Exhaust Systems

Cargo management system

Interior & Exterior Trims

Instrument Clusters

Roof Rack Systems

PROFESSIONAL HIGHLIGHTS

Tolerance Stack-up

GD&T, APQP

DFMEA, DVP&R, PFMEA, TRIZ, ARIZ

WERS Release System-Ford

GM EWO TWO

Lean Manufacturing, 8D

Program Management, MSU

1.GENERAL DYNAMICS

Mechanical Engineer 12/2023-7/2024-CONTRACT

Mechanical Engineer working on XM30 Tank components for military. Responsible for components from concept to production (cradle to grave).

Worked on multiple components with all cross functional groups including quality, manufacturing, GD&T, logistics and materials. Incorporating all the issues per review from each functional group. Met all release dates per the engineering release plan

Generated DVP & DFMEA with for each part to identify all failure modes. Put controls in for all the high RP numbers to mitigate all failure risks.

Directed CAD for all part design and used Team Center to release the parts (Active Work Space). Used power point for documenting initial design direction. Parts were designed correctly per the vehicle fit requirements.

2.FLEX-FARMINGTON HILLS, MI-CONTRACT

Mechanical Engineer 8/2022-11/2023

Mechanical Engineer working on interior lighting systems and Over Head Console for multiple

Worked on parts from concept to production supporting 4 customers. Supported customer at the plant and development process for all part inside and outside vehicle. Worked on quality issues and manufacturing. Supported all issue from Flex plants to customer plants. Customer provided repeat business for urgency and supplier appreciation.

Responsible for programs from concept to production (plastic, electrical, and metal components). Meeting all deliverables for cost timing and requirements. Directed CAD to develop CAD drawing for Flex and customers, GM, Honda, Nissan, and Ford.

Designed and developed plastic parts, conducted lab testing and root cause analysis for failure and customer concerns. Used 8D methodology and root caused one part on overhead console that failed, found root cause and fixed issue meeting quality requirement for customer.

3.FORD-Dearborn, MI-CONTRACT

Product Engineer / Program Manager 5/2021-2/2022

Program Manager working on all deliverables for all Ford programs on ADAS technology.

Part included Camera, Radar, Lidar and other modules for communication. Managed and tracked all timing, testing, and all requirements for DAT (driver assistance technology) requirement for vehicles. Met all targets per the timing plans.

Working on test equipment purchases for Ford test lab, Used Ariba system to procure parts. Met all timing for test lab parts. Tracking all deliverables through system JIRA. Close all issue with JIRA to meet vehicle timing plans per milestones.

Met with all suppliers for timing and testing per milestones for vehicle let DAT 1.0. All DAT issues were closed per vehicle timing.

4.ADIENT- Plymouth, MI-COVID Layoff

Product Engineer (Seat Complete) 2/2020-6-2020

Worked on seat complete from concept to production. Design release engineer for several programs for North America. Tracked all testing timing and results prior vehicle launch. Met all testing requirement for vehicle launch.

Worked on cost reduction ideas for seat complete. Generated 3 ideas for cost reduction implanted all 3 and booked the target for model year.

Identified one material ingress egress failure. Used 8D root caused issue and solved it to pass all testing

Used PLM to document all open issues for meetings and issue resolutions. Issued reports for people with no access to PLM. Reports were used as a support aids at high level meetings.

5.FORD-Dearborn, MI-CONTRACT

Sr. Lead Engineer and Program Manager, 3/2013-12/2019

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

Designed, developed, evaluated, and ran plant trials. Got management, PVT approvals and implemented changes and booked savings. Exceeded cost targets for 2015, 2016, 2017 & 2018. Recognized by the chief engineer for exceeding targets. Recognized by supervisor for saving $2.4 million on one change.

Supervised, trained, and mentored lower-level employees with less experience. All employees received project per the mentoring and training received. Recognized for helping supervisor take on more work on.

Worked on soft trim components from concept to production for design and development. 6 Global programs, China, Europe, 3 Noth America, and 1 export RHD & LHD. All vehicles were worked on at the same time. Met all vehicle timing at the prototype build site and manufacturing plants.

Soft trim components consisted of all NVH acoustic components (dash insulator, carpet, other trim parts), also worked all over vehicle including cargo management systems and powertrain dampening materials for engine and road noise. Supported NVH and met all NVH targets for all vehicles.

Responsible for Program management for multiple programs from initial cost to production tooling and meeting requirements. Tracked cost, timing, requirements, achieved all 3 per program vehicles.

Utilizing CATIA V5, Vis Mockup, and Team Center for developing components and assemblies from cradle to grave. I designed FORD parts and directed suppliers to design parts for supplier responsible designs.

Utilized PLM (Team center) to approve all part designs and illustrations. Supported all suppliers with prints for part dimensional approval. All parts were signed off and met requirement for vehicle builds.

6.NAVISTAR-Lisle, IL

Sr. Lead Engineer / Program Manager Truck 3/2011-3/2013

Lead the engineering team for the development of the full Cab for all trucks. Worked with NX and team

Developing design proposals for Heavy Truck cabs (Interior/Exterior) for rapid prototyping, such as 3D printing, for concept validation.

Planning and securing project deliveries and timing using JIRA. Conducting Root Cause Analysis (RCA) using 5WHY, and 8D to understand how and why the component failed.

Creating and delivering technical documentation in 3D and drawings using CAD Software CATIA and team Center

Using Geometrical Dimensioning and Tolerance (GD&T) to secure robust and tight component packaging.

Analyzing client test data and reports using technical standards from SAE, ASTM, and ISO to determine component and product requirements.

Working with other departments in a cross-functional environment to secure on-time deliveries and component quality. Representing both company and the client in meetings and visit with client suppliers.

Truck included, school bus, medium & heavy-duty trucks for international trucks. Designed & Developed Air-ride suspension, seat & cushion adjusters, back frame & cushion structures for school bus. All Vehicles were launched on time.

Involved in developing DFMEA, DVP&R documentation. Conducted Design Reviews, VA/VE activities, Build samples & coordinate testing. All Testing passed per the requirements. All Cost reduction was booked per vehicle timing.

Program manager supporting a new build site and engineers to supply part to a small new assembly line. Tracked all the part orders. Parts were received on time to support vehicle builds.

Training for PRO E modeling, Program Management, textbook training. MSU 2008-2011

7.TENNECO AUTOMOTIVE-Grass Lake, MI-2008 lay off

Sr. Design Engineer / Program Manager 1/2008-11/2008

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. Released the new wrapping method to support builds at plants and new cells.

Used Catia V5 to design shop tools for assembling CAT bricks, DOC, & DPF. Modeled parts and made prints (CAD) for vendor to manufacture tools for in house shop. All parts were Designed and manufactured. All part used in the build site to manufacture exhaust systems.

Designed 40 different tools using Catia V5 for tooling for manufacturing hot end canning. All tooling was used for hot end canning and tools were used for multiple vehicle production.

8.GENERAL MOTORS- Warren, MI CONTRACT

IP/Cockpit Engineer IP and Floor Console 12/2005-1/2008

Designed & developed IP and Floor console for vehicle refresh. Modified parts for cost reduction.

Met all cost reduction targets

Worked on sled issues and modified parts to pass the sled testing. All testing requirements passed

Per modifications made to the parts.

9.Sika corporation- MADISON HEIGHTS, MI

Design Engineer, Baffle and Sealing 3/2003-12/2005

Designed baffles for sealing body cavity concept to production. Mocked up parts in the shop, bent cavities and ran test in house to validate parts in lab. Supported GM build site and plants. All the parts passed the sealing requirements.

Actively involved in product verification & validation, competitive product benchmarking, pilot build & launches.

10.

EDUCATION

BSME, Mechanical Engineering

Wayne State University

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