Darrell Simmons Email & Phone Number

United States

As the Project Engineer my duties include planning and execution of product development for Tracked Programs. Also responsible for working with product teams to manage the project schedule, cost, processes, and risks for engineering-related activities on the program. They will help manage a large team matrixed from the functional organizations.Primary Responsibilities • Assist in managing the project using GDLS processes to meet cost, schedule, and scope• Support the preparation, review, and approval of products / Control documents / Design reviews• Support the management of the Engineering Release Plan (ERP) for Models and Drawings• Execution of assigned daily Control Account Manager duties• Help control the project using Earned Value principles, Metrics, Variance Reports, and changes• Support issue resolution and risk mitigation planning and corrective action activities• Review and approve scope, budget, decisions (technical / project), and formal deliverables

United States

Beaver Aerospace, Livonia, MI April 2021 – October 2021 Project Engineer (6-Month contract with Belcan)Assist with the scheduling, planning, forecasting, resourcing, and managing of technical activities to ensure project accuracy and quality. Was responsible for the engineering and technical disciplines of ongoing projects and will establish inspection criteria for the proper implementation of all the elements of a project.Primary Responsibilities • Preparing, scheduling, coordinating, and monitoring assigned engineering projects.• Formulating project parameters and assigning responsibilities to the most capable employees and monitoring the project team.• Interacting with clients, interpreting their needs and requirements, and representing them in the field.• Performing quality control tasks on budgets, schedules, plans, and personnel performance and reporting on the project's status.• Cooperating and communicating with the Project Manager and other project participants and collaborating with Senior Engineers to create more efficient project methods and to maintain the project's profitability.• Reviewed the engineering tasks and initiating the necessary corrective actions.• Developed specifications for the project's needed equipment.• Created frameworks to measure the project's metrics and data collection.• Establishing field test methods and methods for monitoring the quality of those tests.• Ensured the project's compliance with the applicable codes, practices, policies, performance standards, and specifications.

Rochester Hills, Michigan, United States

Managed engineering commodities activities for Chrysler’s pre-launch programs (Modula rack designs used for specialized department on-line assembly programs) including managing design concepts to meet customer’s packaging, assembly, specifications, timing and cost targets. • Tracked program timing to assure meeting customer and internal gate events.• Conducted design reviews with internal/customer team members.• Supported pre-production event runs at manufacturing plants.• Communicated project and task status to management.

Auburn Hills, Michigan

Sr Program Engineer responsible for managing engineering activities for fluid transfer product programs (Fuel rails systems for Specialty Engine programs) Job duties /responsibilities include working on fluid product designs to meet customer’s product, packaging, assembly, specifications, timing and cost targets - Engineering activities: • Conduct Design Reviews with internal/customer team members.• Review 3D math data with design team and manufacturing engineers• Review automotive manufacturing feasibility for prototype and production requirements.• Conduct supplier technical reviews.• Submit DV and PV testing per customer’s requirements.• Support run-at-rate events at manufacturing plants• Track program timing to assure meeting customer and internal gate events.

Sharonville, Ohio

Project Engineer responsible for multiple programs – feasibility, process planning, launch and daily production.Programs include brazing, bending, machining and assembly of fuel rails and fuel tubes for high-pressure GDI fuel systems. Work includes manufacturing, materials, design and process activities to resolve internal and customer issues for quality, machine capacity, process speed, packaging and other.• Analysis of product design/changes, create plans to implement these successfully.• Work with machining department to verify high-quality tube cutting to assure good endforming.• Work with manufacturing group to develop and specify new equipment technology – robotics and high-volume production and inspection techniques.• Primary customer liaison for design and customer plant quality.• Project: Developed a 1-piece bracket assembly for high-volume capability, and labor cost savings.• Project: Designed and installed (w/ Mfg team) the first high-volume power bender with vision system in Ohio plant, saving the cost of two workcells with multiple operators, and increasing capacity.• Project: Developed advanced endform measurement technology and equipment for 2-side endform sealing to assure endform integrity, reducing high-frequency measurement time (labor).• Project: Developed a digital information system for each workcell, which is being installed plant-wide, to have in-cell training, measurement and other information available to front office and off-site for all workcells. Decreases training time and operator errors.

Florence, Kentucky

Resident Quality Manufacturing Engineer for Martinrea-Honsel-Tafime plant in Queretaro MexicoPhoenix Engine program - member of the launch team to design and build a new 3.2L cast aluminum engine block. Responsible for evaluation/approval of quality operating system, validation of measurement system and control plans for engineering specs/material requirements.• Review/investigate root cause to verify 8D’s, coordinated PPAP/ SREA activities.• Analysis of product design/changes, identify and implement quality improvements/inspection plans.• Support production/manufacturing machining processes to ensure that engine block meets specifications.• Worked effectively as a liaison with Eagle-Linamar plant, Chrysler North-American and Mexico engine plants and Tafime Mexico plant to solve problems/develop solutions; review/investigate inspection failures.• Applied advanced engineering methods - Six Sigma, Lean Manufacturing, Optimization, other.• Monitored and tracked supplier quality issues and delivery schedules to meet launch requirements.• Project: Analyzed crank case failures to reduce porosity in process, resulting in failure rate reduction from 33% to less than 5% (met specs), increased capacity +8% and cost savings of $160K annually.

Sharonville, Ohio

Resident Quality Manufacturing Engineer for GKN Sinter Metals, Shanghai Automotive Gear Works and Magna Powertrain-Pullmatic ManufacturingMember of the manufacturing engineering team for the 6F/X22 Ford/GM joint venture program to design/build a new 6 speed FWD/AWD transmission. Responsible for multiple product launches, quality, process, design change and cost reduction activities, working with powder metal and stamping products and processes.Responsible for containment and resolution of all quality issues, driving permanent corrective actions at the manufacturing facilities.• Worked with Ford to develop zero defect strategies for supplier Pass-Thru Characteristics.• Analysis of product and process designs to reduce overall product cost through capacity increase, labor reduction, material optimization and defect/scrap reduction.• Worked effectively as a liaison with all departments in Ford power train operations to solve problems and develop solutions; reviewed and investigated results of inspection failures.• Monitored and tracked supplier quality issues and delivery schedules to meet launch requirements.• Project - Oxidation problems/ rejects: analysis and recommendations led to $200K savings annually• Project – Excessive part contamination: Developed an off-line cleaning fixture to resolve downtime issue, with no process time impact, increased part capacity +15%, saved $120K annually in rework/scrap costs.• Project – Major containment/measurement issue: Certified/Installed gages and did personnel training to address 4 months of inventory, reduced rejects from 46% to 2%, saving $100K in rework cost and $65K in supplier chargeback cost.

Dayton, Ohio

Supervisor/Team Leader• Supervised 80 people from the production teams across 3 shifts; ensured quality standards were met.• Maintained smooth production flow/shift schedules, conducted training.• Analyzed malfunctions on cutting machines (Gerber 3500/GTXL); solved mechanical/software problems.

Dayton, Ohio Area

Space Age Concepts International – Dayton, Ohio Electrical Engineer• Identified/resolved issues for the electrolysis static coating systems process.• Generated significant time and money savings by resolving serious contamination problems.

Dayton, Ohio

Operations & Performance Engineer • Developed software statistics for predictive review/measurement of company’s capacity and performance.• Monitored operations/resolved issues with computer systems including security infringements.

Dayton, Ohio

Project Engineer• Assisted with design of control systems, automated equipment and robotics using AutoCAD.• Supported GM/Boeing/Others by implementing Visual Basic and Control Systems Lateral Logic Program Language to program Allen-Bradley PLC equipment.• Tested prototypes and final product designs and ensured performance met or exceeded quality standards.