BEV Thermal Management System Design- As Sub Project Leader, led team members to develop BEV thermal management system (TMS) layout and solve part interference issues. Managed vehicle 3D data and released drawings- Led team members to create technical documents for teaching new associates to design TMS. Created detailed procedures to help members understand process and requirements- Created TMS team activity plan, managed budget, and conducted regular reports to management10AT Drivetrain Design- Solved ICE vehicle 10AT transmission TC case clearance issue and breather failure problems, analyzed root causes, and created reports to prevent future problems- Developed new methods to measure part clearance and coached associates- Created 2D drawings and 3D models, reviewed simulation results, and provided technical judgments

F-150 & Transit BEV gearbox design and analysis- Selected eAxle gearbox design to fit in 10+ BEVs including F-150, Bronco, Transit, etc. Saved cost by reducing eAxle complexity- Led CAD and CAE engineers to design and analyze bolted differential with eLocker, saved cost, reduced package size, conducted tolerance stack up calculation- Led CAD designers to design transmission case, wiring, baffle, cover, etc.- Trained engineers to conduct gearbox inertia and spline calculations, durability and dynamic analyses- Designed and analyzed gears, bearings, shafts, splines for BEV gearboxes, managed bearing suppliers- Led weekly cross-functional meetings with chassis, mount, half-shaft, motor, inverter and VA teams- DFM and DFA, led weekly interface meetings with manufacturing and assembly teamsEdge, MKX & Transit HEV hybrid transmission design and analysis- Designed hybrid transmission to fit in HEVs including Edge, MKX and Transit, saved cost and weight by reducing transmission axial length- Determined architecture and kinematics, managed cross section and BOM, designed gears and splines- Improved design and saved cost and weight on One-Way-Clutch and output flange by conducting durability analysis (FEA) - Solved hardware break issues by calculating dynamic road load with multi-body dynamic analysis (MBD) on hybrid powerplant modelsPower transfer unit (PTU) spin loss testing- Co-led PTU spin loss testing project, managed budget and created project schedules- Organized cross-functional meetings to perform tests at Ford lab. Purchased hardware, determined PTU break-in and testing procedures, solved onsite problems, monitored testing and analyzed test data - Compared Disconnect and Integrated PTU spin losses, supported fuel economy analysis- Led HEV powertrain hardware system and driveline PTU design

- Designed and released marine propulsion units components, including propeller, nozzle, and mechanical components- Worked with purchasing and suppliers to manage part cost, technical reviews and supplier changes- Trained engineers to do design and FEA, led CAD group to design thruster components- Conducted DFMEA and root cause analysis, created lessons learned documents - Developed company standards for structural design and FEA procedures for sufficient structural design- Created fabrication, machining, assembly, and GA drawings, familiar with GD&T and stack ups- Conducted fatigue analysis, buckling analysis, modal and harmonic analyses of complicated thruster model - Prepared detailed FEA reports and presented to customers to substantiate satisfaction of requirements