Engineer Manager

Robert T. Chafin

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

Aubrey, Texas 76227

Cell Phone 940-***-**** E-Mail: ********@*****.***

SUMMARY

Registered Professional Engineer (Texas). Mechanical engineer and engineering manager with over 30 years experience in the automotive/transportation industry. Possess a history of innovative solutions to engineering problems. Expert in solving automotive noise/vibration problems. Skilled in the design of powertrain and chassis systems and components. Familiar with jig/fixture design, metal joining, forming, fabricating, machining and assembly techniques. Experienced in the application of SPC to tolerancing, in design for manufacturability, and in lean manufacturing methods. Member, Society of Automotive Engineers. PC/MS Office/MS Project/LMS Test.Lab/Head Acoustics "Artemis" literate.

EDUCATION

• Bachelor of Mechanical Engineering - Auburn University; Auburn, Ala.

• Master of Science, Mechanical Engineering - Wayne State University, Detroit, Mich.;

PROFESSIONAL EXPERIENCE

Senior NVH Engineer: September, 1998 – Present

Peterbilt Motors Co. (division of PACCAR, Inc.), Denton, Texas; Manufacturer of Class 8 trucks

Responsibilities:

• Establish noise & vibration test capabilities in Denton, and develop NVH training program.

• Plan and implement solutions for NVH (noise, vibration and harshness) problems in current and future model trucks.

• Serve as company-wide resource for noise and vibration: develop interior sound packages and means to pass legal noise tests; serve as structural vibration resource, conducting animated modal analysis.

Accomplishments:

• Applied results of Transfer Path Analysis (source-path-receiver analysis) to N/V solutions in existing products & to validation of FE models

• Prepared capital projects to establish N/V analysis capability and passby noise test site in Denton.

• Solved numerous exterior (passby) noise problems on production and new models.

• Developed application of 6-Sigma and D.O.E. methods to pass-by noise problems, reducing system costs.

• Established noise level and sound quality (psychoacoustic) and tactile vibration targets, & planned program to reach Best-in-Class performance in next-generation trucks, through testing current & competitors’ products.

• Wrote training materials and delivered lectures for introductory noise/vibration classes within Peterbilt.

• Proficient in use of LMS Test.Lab and Head Acoustics Artemis acquisition and analysis software.

Engineering Manager (Automotive Div.): January, 1997 – December, 1997

American Boa, Inc. (ABI); Cumming, Ga., (a subsidiary of IWK Regler und Kompensatoren GmbH; Stutensee, Germany) manufacturer of metal bellows joints and exhaust flexible couplings for automotive applications

Responsibilities:

• Reported to the president of American Boa

• Managed a department responsible for both product and manufacturing engineering

• Interfaced with customers and end-users (Big Three) in the application of ABI products

Accomplishments:

• Trained staff in the application of analytical and subjective NVH evaluations to noise and vibration problems.

• Led move to cellular lean manufacturing, idling 50% of existing plant machinery.

• Obtained and launched new Chrysler business (LH car line) increasing ABI-Automotive sales 70%. (putting idled machinery to use)

Reason for leaving: Reorganization of ABI management structure by the parent company.

Senior Manager, Manager, Exhaust Product Engineering: 1989 - 1997

Calsonic North America, Inc. (CNA), the U.S. division of Calsonic, Inc, Tokyo, Japan

Calsonic Technical Center (CTC) - Tennessee, 2/89 - 7/95

Calsonic Technical Center - Michigan, 7/95 - 1/97

Responsibilities:

• Reported to the vice-president of engineering, Calsonic Technical Center.

• Managed engineers, graphics, test, and prototype sections located both in Mich. and in Tenn. (total 22 heads).

• Managed department compliance with QS 9000 procedures with respect to design control, testing, and prototyping.

• Operating and capital equipment budgets in excess of $1.5 million per year.

• Interfaced with customers’ purchasing and engineering personnel.

• Training and leading staff in the application of acoustic and vibration analysis techniques to product problems.

Accomplishments:

• Led design, prototyping, and development of all exhaust systems and catalytic converters built by Calsonic in North America; this included Nissan vehicles, Villager/Quest, Escort GT, Gen5 Corvette, and Mercedes ‘M’-Class.

• Instrumental in getting the business for the Gen5 Corvette, and for the Mercedes-Benz utility built in Alabama.

Reason for leaving: Dissatisfaction with 1995 move separating engineering management in Michigan from engineering design and development, and manufacturing activities in Tennessee.

Senior Product Engineer: 1976 - 1989

Ford Motor Co., Light Truck Operations, Dearborn, Michigan

• 11/86 - 2/89: Special assignments:

1) Legal noise compliance/exhaust development for the 7.3L Diesel and fuel-injected 7.5L gas engines for pickup and van platforms. Improved testing procedures and applied design-of-experiments methods. Developed innovative acoustic treatments for Diesels.

2) Development of an exhaust system for the new Explorer utility vehicle, to improve subjective sound quality.

• 11/81 - 11/86: Exhaust Design Dept. – Design/release complete exhaust systems for the Diesel and 7.5L gas engines from concept through manufacturing feasibility and launch. Designed first application of stainless steel to light truck exhaust; designed first non-asbestos exhaust gasket at Ford Motor Co., and laminated-steel piping to reduce radiated noise. Developed analytical method for relating flowbench measurements to exhaust backpressures.

• 7/78 - 11/81: LT Development Dept. - Exterior noise test/exhaust system development for compliance with local, state, and federal legal requirements. Identified/treated various contributors to total vehicle noise, including cooling fan, air intake, and tire noise. Pioneered the application of animated modal analysis to light truck exhaust systems. Developed the Ford test for tire noise contribution to exterior noise.

• 2/76 - 7/78: LT Devel - Did powertrain NVH work in the lab and on the test track, addressing: engine balance, valvetrain, accessory drives, cooling fans, and air intakes. Used analytical methods such as modal and FFT analyses.

TRAINING

Completed training in the following areas:

• DOE, SPC, Des. for Mfr, FMEA, GD&T, Decision Making/Kepner-Tregoe, Quality Function Deployment (Ford)

• Public Speaking, Management, Technical Project Management, FFT Analysis (Calsonic)

• ATQPS (Arvin Total Quality Production System) Lean Manufacturing training; (American Boa).

• Six-Sigma: Management Overview; Green-Belt and Design for Six-Sigma training; Managing Employees II (Peterbilt);

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