Automotive Designer / Leader - Plastic Parts UG-NX

12/2001 – 12/2003

Contacted by an International Recruiter to join the Cost Reduction Engineering Team at OPEL AG. Responsibilities included the evaluation of current production models to identify components and component systems that could be produced in a more cost efficient manner while maintaining quality, feel, and safety

I was part of the Wheels-Brakes-Tires group, where we found cost savings in several over-specified materials. We also achieved cost savings in one model by eliminating the spare tire - replacing it and all supporting hardware with an on-board air compressor and aerosol tire sealant. This change was responsible for not only a savings in production cost, but also a reduction in mass. This solution is now commonly implemented on vehicles worldwide.

Other areas of focus included working with leather and trim suppliers to find lower cost alternatives for various grades of steering wheel leather, and for less expensive but high quality interior finishes.

- Cost Reduction Team to reduce production costs of Fuel System, Wheels, Brakes, Tires & Suspension Components.
- Worked to eliminate the spare tire from the Opel Zafira.
- Replaced the Jack, Tire Tools, and Spare Tire & Wheel with an air compressor and liquid sealant.
- Sourced all components from outside suppliers.
- Authored revisions to the vehicle operator’s manual.
- Analyzed Fuel System components of current production Vectra to look for cost savings.
- Identified several material changes, and validated them with crash tests.

Siemens Nx

1/2000 – 12/2001

Recruited by MSX International to assist with A-Class surfacing of Interior Trim Components for OPEL Astra interior Door Trim, Speaker Bezels, Center Console and Instrument Panel. Also responsible for the A & B Surfacing of Grill Inserts for OPEL Vectra.

- Unigraphics Design of interior trim components for Opel Astra.
- Class A-Surface development from point clouds.
- Speaker Bezel A & B Surfacing from point clouds.
- Speaker Bezel B-Surface design.
- Complete Opel Vectra Grille Insert design from styling surface.

Siemens Nx

1/1999 – 12/1999

Seat Foam and Door Panel design with UGNX
- Unigraphics surfacing of Seat Foam from point clouds.
- Unigraphics Design of SAAB interior trim components, including Center Console & Door Panels.
- Unigraphics Design of foldable rear cup holder.

Siemens Nx

6/1997 – 4/1999

- EV-1 Electric Car Program follow up design revisions.
- Electric Postal Vehicle Prototype - Electric propulsion system integrated in to a US Postal Vehicle.
- PNGV Interior Buck Design Overview.
- PNGV H-Point Studies.
- PNGV Roof Structure from typical sections.
- PNGV Frontal Area Analysis.
- PNGV Wind Tunnel Testing at GM Warren Technical Center.
- PNGV Tire Compound Analysis and Rolling Resistance Testing.
- PNGV Tire Envelope Creation.
- PNGV Parallel Hybrid complete vehicle packaging layout.
- Responsible for the compilation of all components in one assembly, and the mediation of packaging conflicts.
- Acted as a liaison between GMATV Design Group and GM Management for weekly progress reporting.

Siemens Nx

3/1995 – 2/1997

GMT-800 Truck Program
- General Motors Truck Program chassis design.
- Supervised a team of 12 draftsmen.

Siemens Nx