Project Manager Engineer

WAYNE C. GRAVES

*** ****** *** / ***** ***, MI **067 / 248-***-**** / ************@*****.***

July 2002 to present: Advance Product Engineer, NetShape International (sister company to Shape Corporation), Novi MI – Developed advance products made with new technology to meet OEM’s specifications; like Toyota Motor Company. This was accomplished by authoring the following: product development flow-charting for strategic planning, test plans for initial R&D and final validation, DFMEA, one-page decision matrixes, and final product DVP&R. Used R&D test data and CAE results to realign development plans to reduce risk. Communicated ideas and product results to customers through written and oral presentations. Managed cross-functional engineering teams that have been awarded $55M for (25) low speed bumper to bumper and (3) pedestrian energy absorber designs. Maintained a CAE hit rate of 2:1; two simulations to each “passing” result. Improved this ratio by 60% over past two years by applying Toyota principles. Developed, submitted for approval and maintained product resource budget.

o Certified to run low-speed bumper test equipment to evaluate products per CFR 49 Part 581, CMVSS 215 and IIHS Low Speed Bumper Barrier testing.

o Able to run Instron mechanical tester with 15K load cell and Bluehill software for R&D and continues validation.

o Performed editor and proof-reader responsibilities of SAE papers under the Bumper, Fascia and Grille category for publication in ’06, 07’, 08’ and ’09 World Congress. Assigned by SAE Bumper, Fascia and Grille coordinator 2006-2009.

o Developed two energy-absorbing products adopted by the European Research Console for Automotive Repair (RCAR), RCAR use these devices to determine insurance rates for vehicles in Europe. These devices are also used for IIHS ratings.

o In 2008-2009 Netshape International employee appraisal regarded “planning skills” as “best-in-class” by supervisor.

May 1996 to July 2002: Product Engineer, Collins & Aikman, Troy MI - Provided the “engineering expertise” in the development of fascia assemblies. Worked on seven fascia front and rear programs that included design for injection molding and sub-assembly that maintain quoted cycle time. Managed the design and release of CAD data. Managed programs timelines by Project Management Institute guidelines. Developed and maintained component & sub-assembly DFMEA, DVP&R, bill-of-materials along with GD&T for assemblies and components.

o In 2001 I managed the successful engineering, development and launch of Jeep Grand Cherokee Overland front fascia system.

o In 1999 I managed the successful engineering, development and launch of Jeep Grand Cherokee front and rear fascia system.

February 1995 to May 1996: Quality Process Engineer, Textron Automotive - MacDonald Molding, New Baltimore, MI Developed quality system for IP assembly and center counsel of ’96 Jeep ZJ. Monitored in-line circuit checks included wire harness, vehicle body module, HVAC module, cluster module, audio system and passenger information module. Responsible for working with engineering for the resolution of interior trim and IP issues. Respond to customer on product non-conformance by performing root cause analysis with writing 8-D reports. Wrote assembly process Control Plans and PFMEA. Used AIAG documentation for PSW and PPAP submission. Conducted first time capability study for process sign off.

o Maintained zero non-conformance issues during launch of 1996 Jeep Grand Cherokee instrument panel.

January 1993 to February 1995 Project Manager / Scheduler, Livernois Engineering, Dearborn, MI: Managed the in-house assembly line for small production runs to make roll formed serpentine fin for Ford Motor Company. Allowed FMC to avoid bank builds by producing a highly capable production process. Performed project manager duties for the assembly of special machines designed to manufacture heat exchanger fin, roll formed tube and raw material accumulators. Coordinate release of assembly drawings, component purchase orders and work orders to maintain timeline. Addressed customer change requests in a timely manor and under budget. Performed product FTC studies for customer final buy-off. Helped develop and implement MRP II system for project control.

o Maintain Ppk levels at 5.0 during the managing of small lot production lines.

EDUCATION

Master of Science in Administration, Central Michigan University August 2002 - Engineering Technology

Master Thesis Title: “Study to Determine the Engineering Opportunity Cost for a 5-MPH Bumper System”, April 2002

Bachelor of Science, Western Michigan University August 1992 - Aviation Engineering Technology

AWARDS AND SPECIAL SKILLS

• US Provisional Patent Application Inventor –Title: “BUMPER SYSTEM WITH FRICTION-FIT ENERGY ABSORBER AND METHOD”, April 2010

• New Technology Awarded from Toyota Motor Company for 2011 Toyota Avalon rear energy absorber. Used a thermoform design that is 37% cheaper with amortized tooling and 35% lighter then TMC’s typical EPP energy absorber.

• US Patent Inventor – US7,228,723 “BUMPER IMPACT-TESTING DEVICE” 2006

• Award: 1st Runner-up, 2004 SPE Automotive Division, “Most Innovative use of Plastic”, Dodge Durango front fascia / step support -Title: “Hybrid Plastic/Steel Truck Front Step Bumper” (Category: Body Exterior).

• Altair HyperGraph 9.0, Altair Hyperview Player 10.0, MS PowerPoint 2003, MS Excel 2003, MS Word 2003, Microsoft Project 2003, Windows XP, Windows Vista & Windows 7, AutoCAD 2000i, Instron 4438 Test Machine, BlueHill V2.12, 3-axis Bridgeport boring mill

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