Expert Details

Expert in Electronics controller Engineer / Industrial Electrician / Manufacturing Safety

Expert ID: 735822 Michigan, USA

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Senior Automotive Electronics Engineer with 33 years’ experience. Industrial Electrician for 7 years prior. Managed embedded controller projects on very high volume vehicle programs, as well as engine (ignition) sensor applications. Having provided robust designs for manufacture in North America, Brazil, and Europe, I have a broad knowledge in electronics design, manufacture, and program deliverables. Experienced as an engineer in the U.S., under three automakers, as well as overseas electronics plant manufacturing experience. Extremely aware of module and sensor failures from design issues, environmental issues, circuit board issues, Integrated circuit issues, electromagnetic interference, and the manufacturing processes that make them. Held suppliers responsible for quality and failure issues. Worked in a Defense (General Dynamics) company for 2.5 years as a Diagnostics Engineer. Authored hundreds of diagnostics procedures to help soldiers troubleshoot their armored vehicles. Seven years prior experience becoming a Journeyman Industrial Electrician, trained in many subjects within Ford Motor company’s vast Rouge Plant Complex; including Electrical Power stations, electrical construction, Substation operation, Transformers and motor theory, DC motors and crane repair, preventative maintenance, High Voltage training and safety, Electrical panel construction, line automation troubleshooting and repair, programmable controller programming and repair, high line safety and heavy press electrical troubleshooting. Also held a residential Journeyman’s License. As an engineer, I co-hold 3 US electronics patents.

Major Experiences:
• Design and release engineer for automotive Powertrain (e.g. Engine and Transmission) controllers in America, Europe, Latin America and Spain. Volumes of over 2M a year.
• Design Responsible for 4 wheel drive controllers (most embedded controllers share similar failure modes and causes) for GM High End vehicles (Escalade, Yukon, etc.)
• Responsible as Design and Release engineer on all Hemi Engine cam and crankshaft sensors (magnetic / Hall Sensors) and dealt with many types of warranty and sensor issues
• 7 years experience as an Industrial Electrician - Troubleshooting a myriad of electrical issues of many type of manufacturing automation and machines.

Expert may consult nationally and internationally, and is also local to the following cities: Royal Oak - Royal Oak

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Education

Year Degree Subject Institution
Year: 1985 Degree: BS Subject: Electrical and Computer Engineering Institution: Wayne State University
Year: Degree: Electrical Journeyman's License Subject: Certification for Industrial Electrician Institution: Henry Ford Community College

Work History

Years Employer Title Department Responsibilities
Years: 2018 to 2019 Employer: Generral Motors Title: Design Responsible Engineer on Transfer Case Control Module Department: Chassis Controls Responsibilities: GM Full Sized SUV Transfer Case Control Module Program on Escalade/Yukon/Tahoe
• Raised the incumbent suppler from a near last place performer to a near top performer to meet the very aggressive product deliverables timeline - with improved function, quality, and vehicle safety
• Expanded understanding of GM’s complicated and immense “Global B” Electrical Architecture (Secure programming, CAN messaging, etc.)
• Acquired an understanding of 4WD Transfer Case control basics and variants.
• Understand Safety issues associated with 4WD engagement / transfer case
Years: 2013 to 2017 Employer: Fiat Chrysler (FCA) Title: Ignition Components Engineer– Powertrain Ignition Systems Department: Ignition Sensors Group Responsibilities: • Tackled all facets/ release of all Hemi Engine Cam and Crank Sensors and resolved all manufacturing and warranty issues.
• Discovered and corrected supplier IC manufacturing processing issue - plaguing the company with warranty. Engaged supplier to apply newer IC technology with no-cost increase.
• Acquired understanding of Hall Effect technology and Magnetic circuit designs to conquer sensor reliability issues. Understand what causes sensors to act sporadically.
• Interfaced regularly with Engine plants / Vehicle Plants to resolve field issues and manufacturing concerns
Years: 2010 to 2012 Employer: Fiat Chrysler (FCA) Title: Technical Cost Reduction Engineer – Powertrain Operations Department: Technical Cost Responsibilities: • Exceeded every annual Cost Reduction Target for Chrysler Powertrain Electrical over 3 years. Submitted over $39M in booked savings against FCA’s Annual Purchase Volume of $800M. Savings exceeded more than 10 times personal quota
• Conducted all day electrical cost reduction workshop or portions of engine workshops
• Garnered the talent of Powertrain subject matter engineers through 17 total engine and transmission teardown workshops. Managed applicable ideas from inception to realization with engineers and suppliers.
• Handled 280 Electrical cost reduction ideas involving ignition and emissions sensors, actuators, and powertrain controllers and pressed their implementation across Powertrain Electrical systems
• Analyzed net cost reduction impact across engine and vehicle lines to understand corporate benefit
Years: 2006 to 2009 Employer: General Dynmics land Systems Title: Diagnostics Engineer Department: Diagnostics Engineering Responsibilities: • Protected the lives of solders in warfare by taking any known potential failure modes of the General Dynamics “Stryker” armored vehicle, (Mobile Gun System variant) and providing the shortest troubleshooting procedure to restore optimal functionality their weapon
• Authored hundreds of electronic “flip-through” procedures with step by step text, graphics and artwork that accurately described in-vehicle troubleshooting procedures. These guided the “in-theatre” soldier to make his vehicle/ weapons system operational, as rapidly and as safely as possible
• Conquered each troubleshooting procedure by understanding vehicle computer start-up sequences/events and schematics for a related failure mode and determine the best course of trouble shooting actions. Boarded military vehicles and analyzed whenever necessary
• Clearly documented, according to the Government’s strict verbiage requirements for Validation and Verification (ValVer) text, styles and rules for procedures
• Trained in counter-intelligence, vehicle fire awareness, hazardous material safety, and blood borne illness safety
Years: 2005 to 2004 Employer: BROAD SOLUTIONS CONSULTING Title: Independant Consultant Department: Responsibilities: • Assisted upstart Taiwanese car maker in methods of Powertrain Electronics test procedures, Design, and Production Validation testing, adding oversight to the general development process of the incumbent Powertrain Module supplier’s (Delphi Electronics) quality
• Created and refined Taiwanese auto manufacturer’s technical specifications
• Taught Taiwanese Powertrain Engineers on basic Powertrain Controller theories of operation
Years: 2001 to 2003 Employer: Ford Motor Comapany Title: Assistant Team Leader Department: Electric Assist Power Steering Responsibilities: • Coordinated Advanced Engineering Team's efforts in meeting hardware deliverables, documentation deliverables and cost targets for 48 volt, Electric Power Assisted Steering (EPAS) control modules.
• Assistant to Electric Power Steering Module Design Team manager:
 Coordinate tasks of the team to ensure concept prototype deliveries meet MRD Dates
 Mentored in the creation process from concept designs to feasible production manufacturing
 Conducted Value Engineering offsite sessions and garnered engineering input from manufacturing, design, purchasing, etc. to reduce EPAS module costs at the next design level.
 Attended and oversaw prototype builds at the Pennsylvania plant to ensure build quality, functionality and testability
Years: 1998 to 2001 Employer: Ford Motor Company - Ford “Cadiz Electronica” Plant, Spain. Title: Design and Release / Manufacturing Support Engineer Department: Product improvement Design Engineering Responsibilities: Cadiz Electronica produced Powertrain, ABS, and Anti-Theft electronics for Ford’s European Automotive theatre. Boarded a four year, Foreign Service assignment in Spain to acquire European module design, electronic manufacturing, and overseas experience.

• Make the transition as an experienced design engineer, to an electronics manufacturing problem solver. Optimize currently manufactured, older designs, with better quality and reduce cost.
• Layout a plan for tests needed to ensure quality on cost reduction and manufacturing driven changes
• Exacted $2M - $5M in cost reductions annually, revamping current module designs with updated printed circuit panel optimizations, materials changes, IC shrinks, mechanical design changes, and general technology improvement changes
• Understand, on a first hand basis, how electronic manufacturing plant processes and equipment can play a vital role in electronic module quality or conversely, create insidious quality issues.
• Provided strategic input to the Powertrain Electronics Manufacturing team to understand/guide contrary driving forces between European and US Powertrain module design philosophies
• Avert manufacturing part shortages, component robustness issues, and running change issues that threatened production shortages or posed warranty concerns
• Reduced total plant part complexity within the plant by directing the creation of a computerized part substitution program
• Coordinated the purchase, teardown, analysis, and report on competitive European module designs that helped reduce cost and improve designs
• Gained European PCM engineering and product market value system perspectives.
• Acquired Spanish as a second language

Years: 1997 to 1998 Employer: Ford Electronics Divison Title: "SLEEC" Team Leader Department: Powertrain Controls Responsibilities: • Choose and lead a Product Design “skunkworks” team to create an engineering break-off design of advanced technology, packaging and system architecture for the Powertrain Control Module Department.
• Direct the team to assess strategic technologies to create a prototype design that involved new package-less IC technologies, miniaturization techniques, underhood vehicle packaging, active cooling, and system integration concepts to demonstrate module and system capability
• Provided first prototypes in less than 14 months with only 3 core engineers - without a dedicated budget
• Design became a forerunner of a super small PCM design to be used in future programs
• Conceived / Jointly held 2 Powertrain Control related patents awarded to the team
Years: 1987 to 1997 Employer: Ford Electronics Divison Title: Design and Release Engineer Department: Powertrain Controls Responsibilities: • Learned all aspects being a module design engineer, from schematic capture, BOM creation, mechanical drawing release, to coordination of prototypes for DV, PV builds.
Key Accomplishments:
• Created PCM designs for European and South American PCM market and launched the first PCM products in the Ford Sao Paulo Electronics Plant, Sao Paulo, Brazil
• Owned PCM module Programs on Vehicle lines exceeding 2 million a year. Never had a major quality issue
• Instrumental in technically saving Ford’s Autolatina program by recreating a critical engine knock detection and control circuit for Volkswagen engines in the Brazilian Market. (Joint Patent awarded for the concept and application - patent later adopted in Europe)
• Dramatically reduced cost the first Brazilian module design where costs “couldn’t be reduced”
• Department “point-man” on many Electromagnetic Compatibility (EMC/EMI) issues which affected module reliability and safety.
• Key player in PCM Design Reviews, Cost/Value Meetings and Product Launch Reviews.
• Trained in many of Ford’s in-house courses on Quality, Statistical Process control (SPC), Electromagnetic Compatibility, and Failure Mode Analysis, Safety, and Intellectual Property Protection.

Design Engineer “C” Ford Electronics, Advanced Technology Office Nov 1987- Nov 1988
• Assess potential emerging technologies are needed by the electronics division by researching trade papers, technical publications and division library.
• Create a vision of new, enabling technologies by interfacing with electronics product managers in technology assessment meetings to understand new product wants and enabling technologies to escalate the divisions technological edge
• Create Division technology roadmaps to enable emerging products and guide product focus.

Government Experience

Years Agency Role Description
Years: 2006 to 2007 Agency: General Dynamics Role: Diagnostics Engineer Description: Created Diagnostics for Stryker Mobile Gun System (8 wheeled mobile Cannon -similar to Abrahams tank cannon). Obtained security clearance for vehilce entry and technology.

International Experience

Years Country / Region Summary
Years: 1994 to 1998 Country / Region: Brazil Summary: Traveled numerous times to Ford Sao Paulo Electronics Plant to launch the manufacturing of Ford Powertrain Control Module for that market.
Years: 1998 to 2001 Country / Region: Spain Summary: Resided in Spain for 4 yeaes as part of a Foreign Service assignment for Ford Motor. Worked in the Cadiz Electronics plant therre as a design engineer to revamp older electronics, desing, acquire electronics manaufacturing expertise and to obtain foriegn experience.

Career Accomplishments

Associations / Societies
Eta Kappa Nu - Electrical Engineering (no longer there)
Wayne State Society of Physics students - (No longer attend)
Licenses / Certifications
Industrial Electrician Journeyman's Certification
Awards / Recognition
I jointly hold 3 patents from my time at Ford Motor Co.
Publications and Patents Summary
Co-Hold Patents:
- Throttle body system with integrated electronics
- Electronic control module assembly using throttle body air for cooling and method thereof
- Knock detection system and control method for an internal combustion engine

Additional Experience

Training / Seminars
3-4 seminars on Electrromagnetic Interfernce of Electronics
TRIZ - Thinking outside the box
Many Value add and Cost reduction meetings
Statistic Process Control / Siz Sigma Training
Failure of Electroics Training

Language Skills

Language Proficiency
Spanish I was quite proficient, but would say I get by now. Some review may get me quite capable depending on the degree of accuracy and setting.

Fields of Expertise

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