John Clark Email & Phone Number

Granger, In, Us

Lisle, Il, Us

Adapt 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.

Belton, Mo, Us

Adapt 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.

Elkhart, In, Us

Lead 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.

Elkhart, In, Us

Develop 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.

Farmington Hills, Mi, Us

Contract PositionDeveloped new part numbers for aftermarket disc brake pad applications.Led process improvement activities.

Farmington 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.

• 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.

• 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.

• Lead two engineers and two designers; coached and instructed task completion and issue resolution.• Approved Engineering Change Requests; key member of Materials Review Board.

• 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.

• 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.

Bs, Mechanical Engineering

Certificate, Plastics Technology

Certificate, Supervisory Management