Battery Experience


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Battery Experience

  1. 1. Battery Experience Program Management Experience Summary of qualifications
  2. 2. Summary of Qualifications • While I have a wide experience in many automotive components/systems. Batteries are one of the critical items I had once developed as an product engineer, and as part of the electrical systems. • As a product engineer I was in charge of the release of design, developing of batteries for several passenger and commercial applications, redesign and recommend batteries for new Onstar applications at GMV, plan and execute the validation requirements for batteries following Delphi and AC Delco standards, and other local test standard procedures. • I worked many years with Duncan, MAC and Delphi. Also as part of the validation process I had to validate many of suppliers designs to homologate as a AC Delco battery for after market purposes. • Participated in the PPAP and APQP process of suppliers validation. • Work as program management leader for several engineering programs following the GVDP process as the stage gate design and quality valve review.
  3. 3. Battery Design and Manufacturing Product Engineer – 1998~2003 – Analyze design release for battery on major vehicle programs – Determine the battery group cranking capacity, Amp-hours and requirements according to vehicle electrical load, and stand-time and autonomy target calculations – Develop validation and design state of requirements for battery – Follow most of the SAE J 537 test procedures for parts validation: • Voltage performance • Cranking capacity • Cold Cranking Test • Charge acceptance • Reserve Capacity • Discharge cycles – durability • Vibration • Self discharge test • Water/Liquid consumption • Nominal capacity • Electric vehicle load and battery autonomy • Stand time test • Durability on vehicle
  4. 4. Battery Design and Manufacturing – Follow ASTM 639 for plastic box validation – Development of new Spill Test procedure for lead/acid batteries – Participate in the Battery APQP and PPAP process for suppliers like Duncan, MAC and Delphi – Certification of Duncan and MAC for AC Delco branding – Work with ChevyStar ( Onstar) battery requirements and electrical consumption designing for several programs – Battery Packaging validation on UGNX – Battery design drawing validation on AutoCAD and UGNX – BOM definition and release for materials
  5. 5. Accomplishment- Projects • Maintenance Free Battery ( 100% sealed technology): develop the first maintenance free batteries, following Delco design for truck and passenger applications: Silverados, Aveo, Forenza, Trailblazer, Grand Vitara, Xl7. Validation of manufacturing process at supplier, and box design validation along with the supplier quality team. • Vibration test: develop new vibration test at 45 degree angle to avoid battery spilling while shipping. • Certification of Duncan batteries as AC Delco brand and Chevrolet brand. • Development and approval of batteries for production for the following GM programs: • GM Daewoo: Aveo, Forenza • GM – Opel : Astra • GM-Isuzu : NPR, FVR, NQR • GM- Brazil: Corsa, Astra • GM NAO: Trailblazer, Silverado, • Suzuki : Esteem, Grand Vitara, XL7
  6. 6. Program Management Experience Product Design Manager : 2003~ 2008 1.Lead the Electrical engineering group: Engineers responsible for engineering change management and vehicle integration strategies for electrical components including Electrical wiring, radios and speakers, alternators, batteries, electronic modules, ChevyStar Telematics components. 2.Lead the engineers within the electrical, mechanical and chemical engineering concepts to release, develop , integrate and validate components following design engineering requirement/standards, the PPAP ( Part Approval Process) development process and APQP development assessment. 3. Ensure electrical integrity of the electrical system for the vehicle 4. Electromagnetic testing for electrical/electronic components 5. Lead mechanical engineer groups to ensure powertrain, brake and fuel systems capabilities and performance, define fuel autonomy of the vehicle in different market conditions, validating the electrical and fuel system integrity
  7. 7. Program Portfolio / Project Management- tools and performance Quality Function Deployment – to comply with customers design requirements Vehicle Design Specifications - to plan for vehicle and systems requirements, comply with the electrical system Validation Cross Reference Index - to plan product requirements for performance and Validation requirements Car Build Test Plan- to plan validation schedule sequence of several testing procedures into the master development plan and comply with GVDP GVDP- Stage Gate process for program portfolio management, to follow quality valves review of different engineering design and validation phases. Project Portfolio Management and Project Management using MS Project Earned Value Analysis to follow up on project progress and performance using MS Project Budgeting plan and execution for portfolio management , including man-hours and project scheduling and cost planning for resource allocation of $3+ million portfolio Strategic Business Plan Deployment according to Global Manufacturing System categories: people, quality, responsiveness, cost, safety, environment
  8. 8. Program Manager Responsibilities Engineering Department Global contact leader with GM Lead Engineering Centers GMBrazil, ISUZU- Japan, Suzuki-Japan, GMNorthAmerica and GMDaewoo -South Korea; to plan localization strategies for components and systems, and to lead the launching process along with the Manufacturing and Quality Departments. Define specific market and customer requirements for the Andean Region with the Lead Engineering Centers in other to ensure proper integration and validation of local components into the local programs. Maintain regular contact with Engineering Centers to update legal and market requirements in order to satisfy regional and international regulations for vehicle safety performance, including SAE, ASTM, FMVSS, JASO,JIS and KS standards. Preparation , revision and approval of component’s final drawings and assembly instructions for manufacturability of local components, locally developed and validated, using AutoCAD , UG NX and VisMockup 3D drafting tools. Technical Assembly plant assistance and support to manufacturing operations before, during and after launching of any assembly program. Assistance to the quality department to implement temporary work orders and engineering changes , production trial runs, quality assistance to problem resolution by using practices like TQM, Red-X, 5 - Step problem, Six Sigma DMAIC
  9. 9. Program Manager Responsibilities Planning and execution of Engineering Department budget ( 3MM+ ) to assure proper operation and efficacy of the engineering, release, integration and validation for CKD (complete knockdown) and SUP programs. Planning and execution of Engineering Department balance scorecard objectives following Global Manufacturing System to comply with the organization’s safety, quality, people, responsiveness, cost and environmental objectives. Safety: ensure proper operation without accidents or incidents. Quality: Provide quality information and data release such as BOM, Drawings assembly instructions , owners manual , service manuals, Car Build Test Plans, Parts Approval information to Manufacturing , Quality and Service Departments People: ensure proper technical training to the team as well as professional development within the organization. Assist RRHH to develop career plans for employees under the Engineering Department. Responsiveness: Plan and execute projects on time to avoid delays on launching products to the market, supported by the Car Build Test Plan to validate parts and components and comply with the program execution. Ensure all legal and safety regulations standards are complied and accomplish by sales date. Cost: Involve the employees in engineering cost reduction strategies to achieve savings in dollars per vehicle a year. (E.g.. Catalytic Converter savings of 20/vehicle by reducing the catalytic load while complying with local regulations) Environmental: Contribute with the environment avoiding laboratory waste or scrap accumulation within the Experimental Engineering, following ISO 14000 standards and procedures.