Andrew Carson Email & Phone Number

New Port, Sa, Au

Milford, Michigan, United States

Conduct Calibration and Calibration verification testing on all GM truck models (both Electric and Internal Combustion Engine) where trailer towing features are an option. As part of this testing, mass estimation accuracy was included. Additionally electronic differential lock calibrations for both EV and ICE vehicles were part of my responsibilities.• Improved performance of GCW mass estimation to achieve +/- 15% target.• Led software/hardware integration and calibration performance… Show more Conduct Calibration and Calibration verification testing on all GM truck models (both Electric and Internal Combustion Engine) where trailer towing features are an option. As part of this testing, mass estimation accuracy was included. Additionally electronic differential lock calibrations for both EV and ICE vehicles were part of my responsibilities.• Improved performance of GCW mass estimation to achieve +/- 15% target.• Led software/hardware integration and calibration performance tuning for Active Chassis featuresCalibration owner for Trailer Braking, GCW Mass Estimation, and Electronic Differential Locker for ICE and EV products.• Identified warranty trends, worked with software and hardware DREs to improve diagnostic algorithm robustness and hardware functionality leading to almost complete reduction in specific warranty claims.• Demonstrated and provided detail of customer experiences to several software teams, and collaborated with them to improve algorithm design and capability of GM vehicle features.• Supported algorithm/calibration improvements for EV trailering to optimize battery range, regenerative braking, and trailer braking performance.• Wrote test procedures and test reports for the work I performed on HIL or in vehicle using tools such as ETAS/INCA, Intrepid NeoVi Fire2/VSpy as well as Vector HW/SW.• Experience with MatLAB tools and SIL.• Root caused deficiencies with GM feature technical specifications and worked with the product feature owners to have these documents updated, and with the hardware DRE and supplier to improve the product. Show less

Warren Technical Center

It was my task to lead a small team of component assembly engineers to deliver on time, without open issues and on or underbudget the fuel system for GM truck SUV programs. I also needed to analyze warranty to determine if failure trends were developing.• Delivered MY21 and MY23 T1SUV fuel systems on time, with zero issues at start of production.• Mentored and trained new DREs in the GM processes and the reasons behind them. • Trained new DREs in how the various components of the… Show more It was my task to lead a small team of component assembly engineers to deliver on time, without open issues and on or underbudget the fuel system for GM truck SUV programs. I also needed to analyze warranty to determine if failure trends were developing.• Delivered MY21 and MY23 T1SUV fuel systems on time, with zero issues at start of production.• Mentored and trained new DREs in the GM processes and the reasons behind them. • Trained new DREs in how the various components of the fuel system worked and interacted with system as a whole, to deliver fuel from the tank to the engine as efficiently as possible while still meeting emission standards.• Developed service operation cost saving alternatives which also delivered an 60% reduction in the number of fuel pump modules needed to service past vehicle models.• Managed, and ensured the changes that presented themselves during the development stages of programs met GM corporate timing milestones and budgets and worked closely with VSE, PEM and cost estimators when unforeseen changes had to occur.• Tracked warranty trends and spikes and investigated when necessary to avoid costs associated with dissatisfied customers. Worked with both GM plants and suppliers to implement containment and long-term corrective action.• Represented and supported the DREs as needed in various program forums to flag or highlight issues/roadblocks needing resolution.• Worked with the global assembly plants at the launch of new model years to ensure smooth transition from old to new parts.• Supported suppliers when they encountered roadblocks or barriers to the flow of information that could impact the part deliverable timing on each model year being supplied.• Led the truck fuel systems team through peer reviews at many milestones covering several model years to ensure quality design free of defects and potential failure.• Black Belt in DFSS. Show less

Port Melbourne, Victoria, Australia

• Lead a team of 8 engineers in India, Germany and USA to develop a new GM global validation procedure for advanced park assist 2 (assisted self-parking) feature that complied with both ISO and SAE requirements.• Validated the various electrical modules/systems in the vehicle for DREs located in any of the 5 GM global design centers.• Collected test data, root caused issues when they arose, and reported findings in relation to validation testing performed in Australia on first usage of… Show more • Lead a team of 8 engineers in India, Germany and USA to develop a new GM global validation procedure for advanced park assist 2 (assisted self-parking) feature that complied with both ISO and SAE requirements.• Validated the various electrical modules/systems in the vehicle for DREs located in any of the 5 GM global design centers.• Collected test data, root caused issues when they arose, and reported findings in relation to validation testing performed in Australia on first usage of global product to my international colleagues in Korea and Germany – Such as Advanced Park Assist.• Performed validation testing on various components/control modules on both test benches and in vehicle, then completed test reports and issue documentation (PRTS) within the program milestone timing.• Completed testing and documentation required for Australian/New Zealand government certification of vehicles to be sold locally.• Peer reviewed global test procedures to ensure they accurately reflected current requirements and certification needs. Show less

Port Melbourne, Victoria, Australia

I was challenged with developing and validating the fuel system for the Australian produced and globally sold GM Zeta platform vehicle, together with root causing fuel system issues both on Zeta and other global GM platforms sold in Australia. I had to work petrol/gasoline, diesel and LPG (propane) fuels.• For five years, managed, planned and performed a number of vehicle certification testing schedules in conjunction with the Validation Engineering group, required for the destination… Show more I was challenged with developing and validating the fuel system for the Australian produced and globally sold GM Zeta platform vehicle, together with root causing fuel system issues both on Zeta and other global GM platforms sold in Australia. I had to work petrol/gasoline, diesel and LPG (propane) fuels.• For five years, managed, planned and performed a number of vehicle certification testing schedules in conjunction with the Validation Engineering group, required for the destination country’s approval process such as for the USA, NZ, South Africa and the Middle East.• Managed supply of parts and teams in the USA performing validation testing to ensure testing completed on time to enable data to be analyzed and reports written for certification approvals.• Development of LPG systems for Zeta 1 - VE sedan and then Ute, which included fuel line routing, fuel level sender calibration, tank fitment and mounting, as well as tank manufacturing requirements.• To avoid program delays, I took on an additional DRE role for the Ute (pick-up) dual fuel LPG (propane) system from the body group for 9 months developing a unique reinforced fuel tank storage area.• Investigated and root caused noise issues in the Chevy Camaro clutch pedal & throttle pedal assemblies that subsequently required the supplier to retool their component to eliminate the noise path.• Managed procurement of long lead time fuel system items to ensure prototype builds were supported. • Planned the resources needed for vehicle test trips required to validate fuel system components in hot weather, cold weather or at altitude, locally and overseas.• Gained RedX Journeyman status. Show less

Port Melbourne, Victoria, Australia

• Delivered greater than 85% of my suppliers to a full PPAP status within program timing, and for the remaining 15% contingency plans for meeting saleable PPAP parts prior to SOP were implemented.• Rolled out new GM Global APQP process to the suppliers for which I had responsibility.• Organized letters of introduction, managed and chaperoned the suppliers from Korea and China when on regular visits to Holden in Melbourne and Elizabeth• Gained a wealth of quality process knowledge… Show more • Delivered greater than 85% of my suppliers to a full PPAP status within program timing, and for the remaining 15% contingency plans for meeting saleable PPAP parts prior to SOP were implemented.• Rolled out new GM Global APQP process to the suppliers for which I had responsibility.• Organized letters of introduction, managed and chaperoned the suppliers from Korea and China when on regular visits to Holden in Melbourne and Elizabeth• Gained a wealth of quality process knowledge due to the numerous manufacturing processes used by the suppliers for which I had been responsible. Manufacturing processes from plastic to metal injection molding, brazing, Die design and manufacture, Metal forging and stamping, Casting, Blow molding. Plastic and metal welding. Show less

Dana Modules And Systems, Hallam, Victoria, Australia

• Progressed from Project Engineer to Managing Engineer-GM Holden projects, which had a budget of $12million and two engineers, three graduate engineers and one process engineer reporting to me. The 30-month project was taken from concept to production on time and under budget.• Due to Dana delivering module assemblies in sequence to a 42min order schedule and frequent late PPAP and wrong module deliveries, I improved the BOM information path between GM Holden and Dana leading to zero… Show more • Progressed from Project Engineer to Managing Engineer-GM Holden projects, which had a budget of $12million and two engineers, three graduate engineers and one process engineer reporting to me. The 30-month project was taken from concept to production on time and under budget.• Due to Dana delivering module assemblies in sequence to a 42min order schedule and frequent late PPAP and wrong module deliveries, I improved the BOM information path between GM Holden and Dana leading to zero late PPAP and zero wrong assembly BOMs entering production.• Collaborated with our commercial team to present a business case to GM Holden that ultimately won the Holden AWD chassis design and suspension module business for Dana.• Led the design of new engine sump cover mounted front differential axle for GM VY2 AWD vehicle. • Progressed from Project Engineer to Managing Engineer-GM Holden projects, which had a budget of $12million and two engineers, three graduate engineers and one process engineer reporting to me. The 30-month project was taken from concept to production on time and under budget.• Due to Dana delivering module assemblies in sequence to a 42min order schedule and frequent late PPAP and wrong module deliveries, I improved the BOM information path between GM Holden and Dana leading to zero late PPAP and zero wrong assembly BOMs entering production.• Collaborated with our commercial team to present a business case to GM Holden that ultimately won the Holden AWD chassis design and suspension module business for Dana.• Led the design of new engine sump cover mounted front differential axle for GM VY2 AWD vehicle. • Implemented training and documentation on workplace procedures to ensure current team was fully aware of the requirements under QS9000 and General Motors APQP process.• Implemented regular customer/supplier team meetings to better track impending tier 2 changes and follow through with PPAP documentation for these changes. Show less

East Bentleigh, Victoria, Australia

• Engineered and managed the design and development of customers’ future model brake actuation systems• Root caused a seasonal ongoing concern of spongy brake pedal feel found in single pot, plated cast iron caliper bodies, through experimentation and data analysis from completed vehicles at customer plants. The root cause was due to a change in PBRs plating process that led to increase in zinc inside the caliper pot bore, and this excess zinc created a galvanic cell in the presence of… Show more • Engineered and managed the design and development of customers’ future model brake actuation systems• Root caused a seasonal ongoing concern of spongy brake pedal feel found in single pot, plated cast iron caliper bodies, through experimentation and data analysis from completed vehicles at customer plants. The root cause was due to a change in PBRs plating process that led to increase in zinc inside the caliper pot bore, and this excess zinc created a galvanic cell in the presence of brake fluid, that ultimately broke down a constituent of the brake fluid into gases.• Evaluated and implemented cost/mass down initiatives from employee suggestions. Show less

Various

Jospin Ltd. – London6th Dec 1994 – 29th Sep 1996Jospin Ltd. is the franchise holder for three McDonald’s restaurants in the outer western suburbs of London, employing in total 160 employees.During my stay in Europe I was employed to be part of the management team for the franchisee and also had the opportunity to work with head office in customer services.Achievements:-• Completed shift running Floor Manager Course.• Improved communication skills enormously… Show more Jospin Ltd. – London6th Dec 1994 – 29th Sep 1996Jospin Ltd. is the franchise holder for three McDonald’s restaurants in the outer western suburbs of London, employing in total 160 employees.During my stay in Europe I was employed to be part of the management team for the franchisee and also had the opportunity to work with head office in customer services.Achievements:-• Completed shift running Floor Manager Course.• Improved communication skills enormously through working in the customer services department.• Introduced improved vat skimmer from Australia, which was evaluated by the Operations Development Department and offered as an alternative to the locally made item.• Wrote a small program to interrogate clock card data bases for invalid time entries.McDonald's Camberwell - Camberwell1987 - 1991Progressed up to Shift Manager.Macdura Pty Ltd - Mildura1984 - 1987Junior Casual staff Show less

Kilsyth, Victoria, Australia

Eaton Pty. Ltd. - Kilsyth.20th Nov 1991 – 16th Sep 1994As a Graduate Engineer, reporting to the Engineering Manager my responsibilities included:-• Issuing and distribution of Engineering Releases/Changes• Drafting & Statistical process control within the axle assembly area• Final inspection/quality audits• Bill of Materials releases to meet specific customer requirements• Design of new components and assemblies.Achievements:-• Developed and… Show more Eaton Pty. Ltd. - Kilsyth.20th Nov 1991 – 16th Sep 1994As a Graduate Engineer, reporting to the Engineering Manager my responsibilities included:-• Issuing and distribution of Engineering Releases/Changes• Drafting & Statistical process control within the axle assembly area• Final inspection/quality audits• Bill of Materials releases to meet specific customer requirements• Design of new components and assemblies.Achievements:-• Developed and implemented new Engineering Release/Change Notice procedures, including writing the E.C.N. database software.• Initiated the design and release of our new model axle housing assemblies for all current customers, and their various suspension systems. • Re-Engineered several of our U.S. brake products to suit Australian customers.• Revised and rewrote the company's current drive-line analysis software.• Designed specialist tooling to enable easier and faster axle assembly.• Wrote drive-line angle calculation software for determining the best drive-line angles according to suspension, axle model, and axle make.Reason for leaving:- Wished to travel through Europe on a working holiday. Show less

Bachelor Of Engineering - Be, Mechanical Engineering

Certificate Iv, Lpg Automotive Technology

This certificate allowed me to legally install, remove and modify LPG components in the state of Victoria, Australia, to motor vehicles.

S-Permit, Commercial Electrical License

This Permit allowed me to legally disconnect and reconnect any electrical device that is hard wired into a circuit breaker box.