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Engineering professional with product development and project management expertise. ISO 9001 environments. Patent holder.• Project management and all phases of product engineering from concept, to product design and development, design validation, and manufacturing.• Innovation in metal, rubber, and plastic part design; mold, pattern, and die design; part material conversion, weight reduction, and design for manufacturing and assembly (DFMA).• Strong background using development tools and methodologies including 3D solid and surface modeling, Finite Element Analysis (FEA), Design of Experiments (DOE), Failure Mode and Effects Analysis (FMEA), Design Review Based on Failure Modes (DRBFM).Specialties:Design: •Plastics: injection molded, extruded •Metals:sand cast, stamped, die cast, extruded •Rubber: compression molded, injection molded, extruded Analytical:•GD&T •DFMA •Tolerance stack-up •DOE •FMEA •DRBFM •5 Why •FTA Manufacturing & Quality: •Plastic mold design •Casting Pattern design •Lean Manufacturing •Kanban •Kaizen •Weibull Analysis •APQP •PPAP •QS9000 •TS16949CAD/CAE Programs: •SolidWorks •Inventor •CATIA •Solid Edge•Mold Flow •FEA
Cts Corporation
View- Website:
- ctscorp.com
- Employees:
- 3645
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Cts CorporationGranger, In, Us
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Lead Design EngineerCts Corporation Jan 2019 - PresentLisle, Il, UsAdapt accelerator pedal designs for specific customer packaging envelopes.Developed optimization process for minimizing ribbing with increased strength performance of plastic components.Perform dimensional tolerance analyses.Create system and component FMEAs.Develop DVP&Rs and analyze test results for conformance to customer requirements and government regulations.Mentor junior engineers, designers, co-ops and interns.
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Mechanical Design EngineerSafe Fleet Oct 2016 - Jan 2019Belton, Mo, UsAdapt mirror assembly mounting for new commercial buses.Configure mirror assembly options for specific customer requirements.Develop new mirror product options, embedded monitors, blind spot indicators, etc. -
Engineering Team LeadShield Restraint Systems, Llc Sep 2012 - Jul 2016Elkhart, In, UsLead engineering product group that develops safety belt retractor assemblies and components.Educated associates on product knowledge, DFM, DVP&R, analysis techniques, engineering processes, and project/program management requirements and deliverables.Created and conducted DVP&R and PVP&R for new products.Develop baseline standard DFMEAs for new products.Lead design and process reviews at US and Chinese suppliers.Developed data reduction macros for raw test data that resulted in 95% time savings.Developed modular retractor design that created thousands of configurations from less than 50 components. -
Senior Project EngineerShield Restraint Systems, Llc May 2011 - Aug 2012Elkhart, In, UsDevelop safety belt retractor assemblies and components.Create and conduct DVP&R and PVP&R for new products.Develop baseline standard DFMEAs for new products.Lead design and process reviews at US and Chinese suppliers.
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Senior Engineer, Aftermarket FrictionRobert Bosch Feb 2011 - Apr 2011Farmington Hills, Mi, UsContract PositionDeveloped new part numbers for aftermarket disc brake pad applications.Led process improvement activities. -
Senior Engineer, Disc Brake EngineeringRobert Bosch Aug 1998 - Dec 2010Farmington Hills, Mi, Us• Led first brake application project in Toyota history to have zero brake warranty in first six months of production.• Developed first FEA design of experiment for optimizing material volume which reduced caliper housing iron mass 32%.• Led design and process reviews at US and Chinese suppliers. • Reduced design cycle time for evaluating fits and need for FEA by developing custom design tool for rubber bushing compression and sliding resistance calculations.• Created consistent requirements and quick customization by developing interactive generic prototype control plans and FMEAs.• Led Design Review By Failure Modes (DRBFM) with customers and mentored other associates in DRBFM.• Confirmed design met customer requirements by defining and executing testing plans for design and product validation (DVP&R, PVP&R).• Identified design improvement and weight reduction opportunities by implementing reliability testing to failure and Weibull life prediction into development testing programs.• Wrote white paper on proper anti-rattle spring load calculations; published internally in 2006.• Supervised and developed Co-Op students in engineering processes and procedures.
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Senior Development EngineerElco Thermoplastics, Inc Aug 1993 - Aug 1998• Created modular interlocking battery tray design that permitted seven different assembly configurations to be made from two molds in small molding press instead of seven large tools and large molding machine.• Eliminated one of three pieces, reduced assembly time, and eliminated a hinge cracking issue by reengineering glove box latch mechanism replacing metal torsion spring with integral plastic spring.• Saved $15k (compared to commercial thread driven systems) on mold construction by developing custom belt driven unscrewing ejection system for threaded metal insert part mold.• Increased potential business by educating customers on metal to plastic design conversion and considerations.• Reduced mold trials over 50% by performing plastic mold filling and cooling analyses on insert molded designs.• Reduced CAD/CAM maintenance costs 10% while adding capabilities to analyze part design and reduced mold design and construction time over 10% by generating mold tooling from one common model. • Led internal audit team that achieved QS9000 certification on first attempt.• Trained others in 3D solid modeling, FEA, and Microsoft Office programs.• Supervised one designer.
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Senior Development EngineerCooper Industries Ltd. - Anco 1991 - Aug 1993• Developed modular wiper family, rated #1 by Consumer Reports, of 10 assemblies which reduced tooling complexity from 35 molds and dies to 14.• Discovered $1 million+ of avoidable expenses analyzing customer returns for potential design issues.• Implemented fleet vehicle testing program using employee vehicles reducing costs from traditional outside services and data collection time.• Trained others in 3D solid modeling, FEA, and MS Office programs.
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Supervisor Special ProductsCooper Industries Ltd. - Anco 1990 - 1991• Lead two engineers and two designers; coached and instructed task completion and issue resolution.• Approved Engineering Change Requests; key member of Materials Review Board.
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Development EngineerCooper Industries Ltd. - Anco Dec 1988 - 1990• Developed rubber torsion spring bushing wiper arm design which replaced three parts with one.• Optimized part design using FEA and DOE.• Defined and executed testing programs for design validation.
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Project EngineerLabour Pump Company Oct 1985 - Dec 1988• Developed unique components for specialty applications including a non-metallic pump bases for highly corrosive environments.• Conducted dimensional tolerance stack-up analyses.• Reduced design time from 4 hours to 10 minutes per design by creating custom computer application for pump shaft resonant frequency calculation.• Defined and executed testing programs for design validation.• Created performance and efficiency curves from raw test data.
John Clark Skills
John Clark Education Details
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Purdue UniversityMechanical Engineering -
University Of Wisconsin-MilwaukeePlastics Technology
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Indiana University South BendSupervisory Management
Frequently Asked Questions about John Clark
What company does John Clark work for?
John Clark works for Cts Corporation
What is John Clark's role at the current company?
John Clark's current role is Lead Design Engineer at CTS Corporation.
What is John Clark's email address?
John Clark's email address is jo****@****bal.net
What is John Clark's direct phone number?
John Clark's direct phone number is +157426*****
What schools did John Clark attend?
John Clark attended Purdue University, University Of Wisconsin-Milwaukee, Indiana University South Bend.
What are some of John Clark's interests?
John Clark has interest in Volleyball, Wood Working, Model Railroading, Golf, Ice Hockey.
What skills is John Clark known for?
John Clark has skills like Fmea, Gd&t, Lean Manufacturing, Design For Manufacturing, Ppap, Apqp, Kaizen, Product Development, Injection Molding, Design Of Experiments, Root Cause Analysis, Product Design.
Who are John Clark's colleagues?
John Clark's colleagues are Gunjan Barot, Vidhyalakshmi Ramanujam, Shrutika Mohindra, Anca Paine, Muthucheliyan Venkatesan, Karikalan Sivakolundhu, Rajendra Pandey.
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