Resume

MAHBOOB ALAM KHAN

***** ********** ***** #*****, ********** Hills, MI 48331  H: 248-***-**** or C: 313-***-****  **************@*****.***

CONSCIENTIOUS & DEDICATED ENGINEER

Experienced as a Mechanical & Structural Engineer, Structural Dynamics Engineer, and Noise/Sound/Vibration Engineer

Highly skilled and proficient Engineer with more than 9 years of experience within structural & mechanical design and analysis and extensive background in noise and vibration data acquisition and analysis. Solid work ethic, great pride in work projects, and multiple accomplishments within design, research, and development at the component level and system level. Recognized as a creative engineer, good team builder, and solid communicator with exceptional technical and leadership skills in a manufacturing environment. Additional keys to success include:

• Well-versed in rotating components, systems, and machinery, Design for Assembly (DFA), Design for Manufacturing (DFM), Six Sigma methodologies and concepts, and continuous improvement (Kaizen), SWOT Analysis, APQP, PPAP, DVP&R, FMEA, and DOE.

• Keen knowledge and understanding of manufacturing processes and tolerance capabilities such as casting, machining, cold forging, stamping, and molding.

• Proficient in Solid Works, Pro-E, Catia V5, and CAE Methods (FEA and CAD) for design and development of automotive, brake, and power train components.

• Adept in Noise and Vibration data acquisition and analysis utilizing Noise and Vibration tools such as ME Scope, B&K Pulse, LMS, Prosig, HMSIII (Aacehn Head), Artemis, INCA (Interior Noise Contribution Analysis), HP analyzer, ONO Soki driveline balancer, Vectronix, Polytec PSV 40 3D Laser vibrometer, Polytec PSV 8.4 Software, Link 3801, and Pro-Link Software.

• Proactive leader who easily coordinates activities of other team members, communicates well with staff in all areas of operations, and supports production in meeting deadlines.

• Expert user of analytic, synthetic, and empirical approaches with a natural ability to solve complex design problems.

PROFESSIONAL EXPERIENCE

Robert Bosch  Farmington Hills, MI (8/2007 – 5/2009)

Noise & Vibration Brake Development Engineer Contributed to Brake Noise & Vibration development and target setting for Ford current and future programs. Performed CAE unstable modes analysis, experimental modal analysis, and testing of dynamometer noise/squeal, vehicle noise/squeal, and vehicle roughness. Conducted System Operating Deflection Shape (ODS), 3D Component and System Experimental Modal Analysis (EMA), and Correlation of Experimental data to CAE model for counter measure development of varying programs.

• Resolved critical issues with Ford F150 (P415) Platform through changes in friction material for brake pads, adjustments to caliper, rotor, and anchor bracket at component and system level, and anchor bracket and Chamfer modifications for easy implementation and low cost change.

• Researched, sourced, and secured materials for static and dynamic friction properties with low delta between static and dynamic friction for optimum moan performance.

• Completed Disc Thickness Variation (DTV) and Brake Torque Variation (BTV) studies and determined new friction materials for MY10 met roughness specifications as per Bosch and Ford requirements.

• Created comprehensive rear axle brake moan detection and prevention process for current and future programs that included caliper motion, modal analysis, and pressure distribution (Tekscan) studies.

• Developed new caliper design for Future F150 Platforms and vastly improved NVH and taper wear performance.

• Established program for Ford Ranger (P150) Platform that called for change from drum brakes to disc brakes and conducted 3D EMA study on system to correlate to CAE model and identify fixes for 7 KHz and 11 KHz squeal.

• Devised process for casting foundry changes for different components as a Value Analysis/Value Engineering (VA/VE) initiative and performed NVH prove out on components for casting foundry moves that included front and rear rotors, rear calipers, and front caliper anchor bracket for various models.

Dura Automotive  Rochester Hills, MI (8/2004 – 8/2007)

Noise & Vibration Development Engineer Conducted Noise & Vibration development and target setting at component level and vehicle level for current and future products that included power and manual adjustable seats, adjustable pedals, electronic parking brakes, window regulators, manual parking brakes, rear wiper systems, and glass systems. This included modal analysis, sound quality and squeak/rattle performance of parts at the component level and vehicle level. Developed and applied Noise & Vibration structure for acquisition of new equipment and establishment of new facilities for NVH testing and development utilizing

head acoustics Artemis software, HMS III (Aachen Head) for NVH Testing, and MB dynamics shaker system for squeak and rattle testing.

• Identified shortcomings in Noise & Vibration test equipment and facilities, acquired necessary equipment and facilities, and created cost savings related to outside testing with total expenditure of $300K and all costs recovered in 8 months.

• Created and applied squeak and rattle specification for Ford Modular Shifter Program (1.4M shifters annually), and developed a single specification that was applied to various vehicle platforms and utilized in Ford Car Platforms CD, D3, D4, S197, C170, and U387/8, and Truck Platforms U222 and P221.

Aisin Warner Technical Center  Ann Arbor, MI (11/2003 – 8/2004)

Noise & Vibration Validation Engineer Performed transmission Noise & Vibration and functional durability development at component and vehicle level for 6 speed and 5 speed transmissions utilized on the 2005MY Ford Five Hundred, 2005MY Chevy Equinox, 2005MY Mazda 6, and 2006MY Ford Fusion. Developed the gear noise criteria for final, counter, and first gear at component and vehicle level for production of 6 speed Ford Five Hundred transmission. Evaluated pre-production Nissan Altima for MY2005 for 5 speed transmission gear noise and conducted power train dyno durability testing related to GMT 193 ADV plan.

• Resolved the 41st order issue at vehicle level related to torque converter for 6 speed transmission for Ford Five Hundred and high pitch noise issue in Chevy Equinox caused by alternator whine.

Ford Motor Company (Contracted w/Altair Engineering)  Dearborn, MI (11/2001 – 11/2003)

Noise & Vibration Engineer Concentrated on power train and driveline Noise & Vibration development at vehicle level for Aviator/Explorer, Navigator, and LS Platforms. Performed all project activities from concept development through to product launch. Worked on new steering column for 2005MY Explorer, developed new engine mounts, and transmission mounts for 2005 MY V6 and V8 Explorer. Played a key role in launch of 2003MY Aviator, completed work on take off roughness issue, and developed engine mounts for the 2004MY Aviator. Performed numerous driveline sensitivity studies on Aviator and Mountaineer and NVH evaluations for power steering pump for Explorer and Explorer Sport Track.

• Created reduced cost exhaust system for 2004 MY V6 and V8 Explorer while maintaining same level of Noise & Vibration performance, including pass by noise certification for U.S., Japan, and Korean markets.

• Resolved 2000 PRM induction/intake moan from V8 Explorer for 2004 MY and launch issues related to Noise & Vibration for 2004 MY Explorer, first order driveline issue on 2003 MY Aviator, and induction hoot issue on Wide Open Throttle (WOT) for 2003 MY Navigator.

• Devised spec for PLRO to make axle and vehicle sensitivity more robust for first order issue for the LS.

Ford Motor Company (Contracted w/ASG Renaissance)  Dearborn, MI (05/2000 – 11/2001)

Powertrain Program Engineer

Responsible for all Powertrain program activities from Concept to Launch for Ranger including Cost targets, Design Issues, and Project timeline by utilizing engineering tools such as DVP&R, FMEA, 8Ds, APQP, PPAP and WERS tracking and release system.

• Managed all program activities from concept to launch related to the 3.0L V6 engine program for MY2002 Ranger. Delivered the program on time and under budget which resulted in fuel economy improvement of 1.5MPG and cost reduction of $38.91.

Toyota Indus Motor Company (PAK)  Karachi, Pakistan (12/1997 – 11/1998)

Product Development Engineer Created differential cases, bearings, drive axle clips, and differential casing rods. Contributed to product testing, release, and launch. Performed solid modeling and FEA of reinforcement assembly instrument panel and brake engine mounting RH. Compiled information and generated reports on stress distribution, displacement, and cost. Conducted a study for selection of CAD/CAM software and participated in strategic planning for Toyota Corolla model change.

• Performed multiple technical functions at once and successfully met all timelines and cost requirements for Toyota Corolla model change specifications.

EDUCATION & COMPUTER SPECIFICS

MS Mechanical Engineering, Wayne State University, Detroit, MI

BS Mechanical Engineering, N.E.D. University of Engineering & Technology, Karachi, Pakistan.

Professional Development:

Weibull Analysis Certification Course, Society of Automotive Engineering

Computer Specifics:

Operating Systems: Windows 95/98, Windows NT, Windows XP, UNIIX, DOS and Sun Solaris.

FEA Solver: NASTRAN, ABAQUS, LS-DYNA and MADYMO.

CAD Software: HYPERMESH, AutoCAD R-14, PRO-E, Catiav5, Solid works.

NVH Tools: Prosig, Aachen Head, Artemis, HP analyzer, ONO Soki driveline Balancer, Vectronix, LMS,

Polytec PSV 400 3D Laser Vibrometer. Polytec PSV 8.4 , Link 3801, and Pro- Link Software.

Application Software: FORTRAN, BASIC, MATLAB, Labview, MS Word, MS Excel, and MS Power Point.

Contact this candidate