Product Development Engineer
Resume:
DANIEL J. CARVILL
Flint, Michigan 48507
*********@*****.***
CAREER SUMMARY
A disciplined and results oriented product development engineer with extensive experience in exterior lighting and components, body-in-white and door systems. Consistently producing superior results in many different facets of vehicle engineering. Broad yet solid experience in identifying, managing and resolving complex technical and engineering problems, while controlling costs and proactively making decisions to ensure the successful completion of the project. Team oriented, continuous improvement driven engineer that consistently meets the stated goals of quality, piece cost, budget imperatives and vehicle launch timing.
PROFESSIONAL EXPERIENCE
GENERAL MOTORS, Warren, MI
1982-2009
OEM Automobile Manufacturer.
Product Development Engineer – Accessories
2003-2009
Design, develop and released accessories for new vehicle sales. Effectively delivered
high quality accessories that met the piece and tooling cost targets and launched on time with the vehicle.
* Realized a 50% timing improvement, delivering a foldable soft top for the niche market Pontiac Solstice coupe in one year.
* Reduced warranty costs approximately 20% on H2 SUT tonneau cover. Identified warranty issues and implemented design changes to correct the root cause issues.
* Reduced accessory installation cost and time by providing vehicle structural brush guard attachments for GM Brazil.
* Expedited development timing with vehicle engineering and supplier so that the mid-size second row console would meet vehicle launch timing.
* Delivered the Hummer H3 off-road accessory lighting on time after many styling and vehicle attachment issues were resolved.
* Launched the Pontiac Solstice luggage rack, windscreen and bimini top accessories. Key Interface with the design studio to provide styled renderings for quoting and with vehicle engineering to resolve attachment issues.
* Identified and launched accessory lighting products after developing exterior lighting requirements.
Product Development Engineer - Exterior Lighting
1998-2003
Designed, developed and released exterior lighting systems for new vehicle sales. Produced high quality lighting systems for the full size van, Hummer H3 and H2 SUT that met the program budget, quality and vehicle launch timing commitments.
* Reduced headlamp warranty costs approximately 10% by initiating and implementing new leak test procedure.
* Realized a $200K annual cost savings by eliminating the mechanical adjuster on all visually aimable headlamps.
* Realized a $150K annual cost savings by implementing changes to the H2 SUT tail lamp, bumper lamp and main body harnesses.
* Resolved plant launch issues utilizing Shainin root cause techniques.
* Improved lighting system fits utilizing body build data to root cause issues.
Process Engineer - Door Systems
1993-1998
Developed and implemented door hinge, hang and striker set process improvements. Improved door fit and finish while reducing warranty and assembly plant labor costs.
* Resolved critical issues to meet shipping dates for door hinge and pierce tooling.
* Improved door fits utilizing real time torque monitoring for door hinge pierce tools.
* Reused prototype door hinge pierce tooling by implementing common designs.
* Used force-imaging equipment to establish target position for door hinge clamp forces.
* Reduced door hang variation utilizing door-to-door check fixtures and door plug gauges.
* Improved door fits and closing efforts by refining the striker set process.
* Achieved world class exterior fits and closing efforts through the control of door fabrication, door to body openings, door hang and latch / striker positioning.
* Utilized tooling for multiple vehicle programs by establishing common datum scheme.
* Resolved interface issues by targeting the correct door position utilizing build data.
* Refined quality verbatim questions ( CAMIP ) to provide detailed customer information.
Manufacturing Engineer - Die Engineering
1988-1993
* Managed the processing, design, construction and implementation of checking fixtures.
* Improved output reports for check fixture gauge R&R by developing new software.
Manufacturing Engineer - Manufacturing Engineering
1982-1988
* Created surface data using GM Corporate Graphics System ( CGS ).
* Designed roll mill molding sections utilizing CGS.
* Generated five axis N / C programs for panel checking fixtures
EDUCATION
MS, Manufacturing Management, GMI ( Kettering University ) Flint, MI
1992
BME, University of Detroit, Detroit, MI
1982
TRAINING
* Unigraphics V16
* GM Inspect
* Corporate Graphics System ( CGS )
* Statistical Process Control
* VisMockUp
* Sheet Metal Basics
* LK CMM Operations
* Sheet Metal Forming
* Zeiss CMM Operations
* Shainin Problem Solving
* Introduction to Quality Engineering
* Dale Carnegie for Effective Speaking
Contact this candidate