Failure Analysis Program Management

GREGORY D. BOBER

***** ********

St. Clair Shores, MI 48080 E-mail: ***********@******.***

Tel. Cell 586-***-****

LinkedIn = https://www.linkedin.com/in/greg-bober-5850548/ US Citizen, US Passport valid till mid 2026

OBJECTIVE

I enjoy designing, managing teams, testing, mentoring, developing ideas, reducing costs and integrating solutions for automotive electronic products. Structured Inventive Thinking and 6 Sigma methods are used. Let me help guide your products to success. What is your latest challenge?

CORE COMPETENCIES (these were used constantly)

EV PHEV Module, Pack, BMS, Design, Safety testing, failure analysis, Thermal Propagation avoidance

Project Implementation, Program Management, timing and planning

Hardware Software System Interface documentation

DFMEA, DFT, PFMEA, ISO26262, FUSA, TSR, FSR, ASIL, DTC, analysis, reviews, break downs

Failure Stress, Fault Tree Analysis, Fishbone Diagrams, Field Failure Analysis and Failure Reproduction

Requirement capture and tracking for specifications & procedures based on ISO26262, ISO16750, ECE324 rule100, FMVSS305, ISO6469, GTR20, UL58A, UL2580, UN3480, UN3490, UN38.3, SAE J1739, SAE J2464, USCAR, EMC and others for China, Asia-Pacific vehicle markets

12V, 24V, 48V LV systems, 380V to 800V and 1100V HV pack BMS, HVBS and RESS systems

DV, PV, End of Line Test Specifications, APQP, Cpk, Isolation, Arc Over Testing

BMS, BDU design, Fusing Strategies, HV Solid State Relays and Pre-charging circuits

Circuit Design for feature requirements testing (ei. response time from Air Bag input till HV under 50V)

Green/Black Belt Design Of Experiments Worst Case Analysis, Tolerance Stack, Design For 6 Sigma,

Shainin, Red X Methods, and special analysis spreadsheets developed over 30 years

LORA Remanufacturing Procedures and Methods, Cost Reduction and Break Even analysis

CAN, I2C, SPI, RS485, RS232 data communication, DVMM, Micro Ohm Meters, Oscilloscope, etc.

Battery Cyclers up to 900A, use of different size thermal chambers. + sourcing to outside lab services

Service Procedures, Service Bulletin, 8D, 5 Panel, Containment and Corrective Actions

Schematic capture for electronic modules, pack architecture, testers, wiring harness design

Special Early Prototype HV Pack Safety Testing and SOC State of Charge studies

provide creative solutions and alternatives for decision making, project impact planning and evaluation

MS Office applications, Agile and Problem Tracking, Change Control and 4M quality systems

Liaison between OEM, suppliers, internal organizations for contracts, reporting, issue resolution

Coordinated re-Software validating production software for production plants prior to each SW Release.

Remote implementation of BMS and Pack Production End Of Line testing in Korea from USA.

General philosophy… Re-use as much as possible to speed next product turn around, design or set up time.

EMPLOYMENT

May 2008-Jan 2025 LG-Energy Solutions (originally Compact Power Inc.) Troy, MI

HV BMS, BDU and Pack Design, Testing, Validation Engineer and Manager, last position was Technical Specialist

Projects in greater detail: (started as BMS Engineer in 2008 into 2009, then to become a Supervisor in 2010)

Documenting requirements, where” checked, who and how reviewed is significant and safety critical.

This action lead to the creation of the Systems and Validation Departments at Compact Power (early LG-ENSOL)

Designed, coordinated the fabrication, 49 BMS Environmental Test BMS Load Boxes simulating up to 112 cells, BDU and temp sensors for each pack; for use in local LG land Korea labs within 100 days + on site support.

Out Sourced in USA and validated 1 and 5 more Performance Test stations for DV PV BMS Performance

testing, provided on site lab set up here in USA in 90 days timing and within $1M budget

Fabricated load boxes for EMC testing GM Chevy Volt BMS at UL (Novi, MI) + on site support

(promoted to Validation Manager in 2011, leading and growing the staff from 3 in 2010 to as many as 11)

Out Sourced in USA 2 BMS and 5 Pack Performance Test stations for DV PV Performance testing, provided on site lab team support here in USA within 120 days timing and within $750K budget

Hired additional staff to support wiring harness fabrication and increased BMS+Pack testing volume

Worked with team to define an internal LG-ENSOL Troy $5M USD full service environmental test lab

combined 3 organization Mountain Chart showing how project delays and pull aheads effect downstream teams, leading to adding a second shift of lab technicians for 6 years

Re-used obsolete office PCs from IT group with CANalyzer Nodes as test message sources to save over $100K

(starting new role of Technical Specialist in 2020)

BMS redesign and concept proved out for a saving over $25USD per pack on existing FCA PHEV Pack

Provided supporting cell change tolerance stack up for OEM review by making a Pack Level resistance CAE tool

… the re-usable CAE tool also proved HV Bus Bars can be made of Aluminum (potential future savings)

R&D study of IOT, Blue Tooth and optical communication; Pyro Fuses for HV PHEV and BMS implementations

R&D study of 24/7/356/15 Thermal Propagation Avoidance Alarm methods (GTR20 and FMVSS305A)

Small PIC CPU driven boards made to generate EMC signals, test supplier changes, recreate field failures

(saved $800 per hour EMC lab time, and allowed 5 minutes to 2 day warranty improvement idea evaluations)

Analysis and Lab testing of 100V 100A Solid State BDU Relays and Silicon Carbide FET circuits

Proposed Field Service Actions to business Project Managers for discussion with OEM clients

June 2000-Oct 2008 Visteon (ex-Ford Electronics Division) (Jr Technical Specialist) Dearborn, MI

lead small teams, a consultant to engineers and 4 Sr. Managers for Instrument Clusters, Audio and Body Modules

Designed a Containment Action Instrument Cluster PCB to PSW production making 187K units in 5 weeks to avoid shutting down 11 Ford assembly plants with 0R per 1000 Warranty; Saving estimated $4B in Ford revenue and $114M to Visteon profit, was awarded Customer Quality Ward

moved 20000 sq.ft Visteon HVAC Test Lab to ACH Sheldon Rd Plant within quoted budget, and time in 2006

May 1989-May 2000 Ford Motor Company (Design Release Engineer) Dearborn, MI

Successfully changed Consumer Reports “red” circle rating to “half black” rating for 1988 Lincoln Continental

Achieved Thunderbird Super Coupe RE EMC compliance 12R per 1000 to 0R with HW SW redesign

Single pass DVP&R combined with PVP&R test cycle, 5 point performance validation on designs after 1991

Ford EED Landsdale, PA plant yield FTT increased from 50% to 99% with HW redesigns on Super Coupe module

received Ford Customer Quality Team Award in 1994 for Shock Damping Module Subsystem with 0R per 1000

1995 Continental first year warranty rate was 1.8R per 1000, vs 1988’s first year warranty rate over 200R per 1000

1995 Continental was first product trial run of Ford HALT HASS testing methodology

Developed QFD House of Quality to prove DTC fault codes are best saved in EEPROM vs. volatile RAM

Jaguar S Class Sedan HW design re-used to improve WIN126 Windstar and Lincoln DEW98/LS instrument clusters

Mazda J97 cluster documentation communicated via fault trees & picture diagrams to overcome 4 language barriers

US.Patents Over 14 patents awarded between 1990 and 2025, a list is available if needed

EDUCATION

1989 Master of Business Administration, University of Detroit (Detroit, MI) GPA: 3.5 out of 4.0

1986 Master of Electrical Engineering, University of Detroit GPA: 3.8 out of 4.0

1985 Bachelors of Electrical Engineering, University of Detroit GPA: 3.8 out of 4.0

many corporate training courses on ISO26262, FMEA, Design of Experiment, and APQP completed thru LINKEDIN, etc.

SOCIETIES & GROUPS

Engineering Society of Detroit Society of Automotive Engineers

Jaguar Club of North America Vintage Computers Users Group (pre 1980s PC machines)

References and additional information is available upon request

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