Experienced Design Engineer

Stephen Hlopick

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

Marysville, OH 43040

Email: ********@*****.***

Phone: 937-***-****

To obtain employment as a project, design, or manufacturing engineer utilizing my background in project management, design, manufacturing, and quality assurance to enhance my future employer’s product line-up.

Professional Experience:

 Honda Power Sports Research and Development – Marysville, OH (June 2003 to Present)

Title: Design Engineer

• Project Leader (PL)

• Responsible for management of complete design of frame sections to meet development objectives from concept to mass production (Frame sections include: frame body, carriers, exterior plastic parts, fuel tank, seat, and air intake)

• Effectively manage contractors and design engineers to consistently meet development schedules

• Design/develop new vehicle features

o Industry first: double-layer fender design improves stiffness while decreasing part count

o Industry first: multi-layer, blow molded, non-gas permeable fuel tank meets and exceeds 2011 emission requirements

o Honda first: camouflage development involving multi-step plastic pretreatments and hydro-transfer of camouflage film to meet market needs

• Responsible for calculating/tracking total vehicle costs to meet design requirements of vehicle while maintaining cost/profit goals

• Coordinate with suppliers to develop required parts and tooling

• Support prototype builds and mass production launches by verifying manufacturability, assembly, final vehicle quality, fit and finish

• Assess vehicle/part quality issues and determine appropriate countermeasures

• Lead cost down initiatives to meet profitability goals

o Reduced cost via suppliers through improved efficiencies and design changes for component simplification or metal-to-plastic conversions

• Part Designer

• Support Plastic Project Leader for development of parts within a frame and plastic section

• Responsible for creating 2D/3D vehicle layouts & part drawings using Catia V4 & V5 and

Finite Element Analysis (FEA)

• Responsible for creating and maintaining vehicle Bill of Materials (BOM)

• Developed part and tooling cost estimates

• Obtained/reviewed supplier quotations

• Followed design through testing & up to mass production launch

• Manufacturing Support

• Responsible for investigating and defining/implementing appropriate countermeasures related to production quality issues

• Evaluate and implement design change requests from suppliers and in-house manufacturing

• Tooling support by leading design reviews with supplier to optimize gate location, part thickness, overall tool cost and quality

• Honda Japan Support

• Support development activities in Japan including component designs, supplier development and cost consensus through close communication with Honda Japan

• Associate Development

• Responsible for training and mentoring new designers and interns

Education:

 Penn State Erie, The Behrend College – Erie, PA (Aug 1999 to May 2003)

Bachelor of Science: Plastic Engineering Technology

Penn State Schreyer Honors College

GPA: 3.95 on 4.0 scale

Relevant Internships:

 Mercury Plastics, Inc – Middlefield, OH (May 2002 to Aug 2002)

Title: Manufacturing Support Engineer (Co-op)

o Designed and built molds used for vertical injection molding machines

o Designed and built secondary operation equipment

o Lead trial runs of prototype samples and troubleshot preproduction concerns

 Zurn Industries – Commerce, TX (May 2001 to Aug 2001)

Title: Manufacturing Support Engineer (Co-op)

o Set up and troubleshot production molds and prototype samples for

horizontal injection molding machines

o Gained experience running single screw extruders by setting up extrusion

lines for production and troubleshot production quality issues

o Completed Eight and Sixteen Run Design of Experiments (DOE)

 Sipco Molding – Meadville, PA (Dec 2000 to Jan 2001)

Title: Tooling Support Engineer (Co-op)

o Updated prints on AutoCAD and Pro/E

o Trained under mold designers and toolmakers

 Edinboro Molding – Edinboro, PA (May 2000 to Aug 2000)

Title: Quality Control Inspector/Press Operator

o Completed visual and dimensional inspection of parts and identified part quality issues

Computer Proficiencies:

 CATIA V5, CATIA V4, Microsoft Office, Mold Flow, Pro/Engineer, Solid Works

Activities, Honors, and Awards:

 Big Brothers and Big Sisters of Central Ohio

 Inventor of 14 published patents (2 patents pending)

 ORMCRT – Team member for Honda sponsored off-road motorcycle/ATV race team

 Intramural Sports – Captain/player in intramural Honda sponsored sports including softball, basketball and volleyball

 Society of Plastic Engineers (1999 to Present)

 Published and presented original research at ANTEC (2002)

o An investigation of semi-crystalline and amorphous plastics under ultra high shear rates and the effect on the physical properties of an injection molded part.

References: References and transcripts available upon request

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