Phil Suter is a mechanical engineer with over 20 years of experience in the automotive industry seeking a new engineering position. He has extensive experience in product design, quality assurance, supplier development, and customer support. He holds a BS in Mechanical Engineering from Rose Hulman Institute of Technology. His career includes positions at Delphi Automotive Systems, AC Delco Systems, and Delco Remy where he led various ignition system design and validation projects, achieved significant warranty cost reductions, and successfully transferred production lines to new locations.

1. Phil Suter
6994 S. Foster Ridge Ct. Pendleton, IN 46064 • 765-425-6168 • philsuter64@yahoo.com
Profile
Mechanical Engineer with 20 years of experience in the fast paced automotive components industry seeking a
challenging engineering position in the central Indiana area. Qualified in the areas of product design, quality
assurance, supplier development, problem solving, application engineering and customer support.
Education
Rose Hulman Institute of Technology, Terre Haute, Indiana
BS in mechanical engineering, 3.56 GPA, 1986
Member of Tau Beta Pi and Pi Tau Sigma honorary engineering fraternities
Skills
Applications
Microsoft Software - Word, Excel, PowerPoint, Outlook, Project
Technical Prints and Specifications - Fluent in reading product prints, geometric dimensioning and
tolerancing, 3D math models, customer requirements specifications, test specs, and material
specs.
Statistical Process Control - Full understanding of product sampling, process capability calculation,
normal distribution properties (mean, standard deviation, etc.), control limit creation, and gage
analysis.
Product Validation - Experienced with Shainin combined environment durability with step overstress
testing and weibul analysis of failure data to predict reliability.
General Motors Production Part Approval Process - Knowledgeable in required documents including
DFMEAs, PFMEAs, Process Control Plans, Flow Diagrams, Dimensional reports, Capability Analysis,
Product and Process validation reports, Matrial Certifications, etc.
Problem Solving - Have used Shainin Red X and six sigma methodologies.
Engineering Disciplines
Product Design - 12 years of experience including 3 ignition systems, many insert molded plastic
components, stamped and cast mounting brackets, epoxy encapsulation systems, laminated
electrical steel, primary and secondary winding assemblies ranging from low voltage 18 gage wire
to high voltage 42 gage wire, and small electronic control modules This is a small sample of
the types of components I have designed and integrated into ignition systems.
Product Validation - 10 years of experience validating 3 ignition systems used by General Motors
Powertrain. Activities include durability testing, failure analysis, problem resolution, reliability
prediction, and on going warranty improvements
Quality - 6 years of experience in reviewing SPC and test data from manufacturing line and deciding
disposition of nonconforming product. Have written permits to allow deviations when appropriate.
Have defined test limits for automated testing based on normal product performance variation.
Supplier Development - Have traveled to 25 plus suppliers to help solve issues causing scrap, line
failures or field failures. Corrective actions addressed process variation, test escapes and design
weaknesses.
Application Engineering - 7 years of experience providing application support to customers, including
the creation of customer requirement specifications for new products. This role also included
warranty performance tracking and presentation
Work Experience
Delphi Automotive Systems, Anderson, Indiana and Kokomo, Indiana 2000-2008
Senior Product Engineer and Warranty Reporting Manager
• Supervised Delphi's ignition warranty activities including failure analysis, database creation, and warranty
performance reporting.
• Lead all product engineering activities for the Gen 4 coil at plug ignition systems and the Premium V8 pencil
coil ignition systems used on GM Trucks and Cadillac Northstar applications. Activities included: design
reviews with staff and customers, FMEA reviews, project gate reviews, prototype and validation builds,
failure analysis and corrective actions, customer interface on all engineering changes, testing, etc.
• Presented design reviews to new suppliers during initial quoting activities and again in extreme detail once
the suppliers where awarded contracts.

2. Phil Suter
6994 S. Foster Ridge Ct. Pendleton, IN 46064 • 765-425-6168 • philsuter64@yahoo.com
• Supported material cost improvement initiatives by developing design solutions for expensive components.
Solutions included component commonization, material changes, and design changes that reduced material
usage or reduced scrap.
• Performed competitive assessment evaluations of ignition systems offered by competing suppliers.
• Provided product engineering support during manufacturing line moves from Anderson, IN and Kokomo, IN.
to Torreon, Mexico (support included process validation, product validation and customer communication).
• Conducted monthly product focus team meetings with customers to update them on product changes,
process changes, process relocations and warranty performance.
• Trained lab personnel and new engineers to perform failure analysis on various ignition designs.
AC Delco Systems (Formerly Delco Remy) 1996-2000
Product Engineer and Application Engineer
• Lead all product engineering activities for the Premium V6 coil near plug cassette ignition system used on
GM's Oldsmobile V6 applications.
• Represented product engineering during all prototype, launch and transfer activities including process
validations, product validations, and PPAP quality submission.
• Solved epoxy encapsulation cracking failure mode using Shainin multi-vary techniques. Inconsistent part
pre-heat profile was determined to be the red X contributing factor. Product validation was achieved after
corrective action was implemented.
• Translated customer requirements into a Delphi performance and durability specification.
• Visited numerous suppliers to assist with dimensional issues that were preventing PPAP approval. Process
DOEs resolved many issues, others were resolved with design or tolerance changes.
Delco Remy 1986-1996
Application Engineer
• Developed conversion hardware and installed prototype High Voltage Switch ignition systems on test fleets
in Houston, Tx and St. Johns, Newfoundland. This allowed harsh real world testing prior to production.
• Modified Delco High Energy Ignition Coils to perform better at high engine speeds. 100 of these coils were
built and sold the Corvette Challenge Racing Series.
• Presented ignition system technical updates at the annual GM Service Technology seminar to educate GM
instructors, field service representatives, and dealership technicians. This was a good forum to help reduce
quot;Trouble Not Foundquot; ignition warranty returns.
Achievements
Managed a warranty reduction team of 3 engineers that achieved a 50% reduction in warranty failure rate
year over year for 3 consecutive years (2005-2008)
As lead product engineer for 3 high volume ignition systems I was able to validate all 3 on time while
achieving the required reliability. Additionally, all 3 enjoyed excellent warranty
performance with less than one incident per thousand vehicles at 360 days of exposure and
less than 2 incidents per thousand vehicles at 3 years of exposure
As part of a cross functional transfer team was able to transfer 3 ignition manufacturing lines from
Indiana to Torreon, Mexico on time and without any adverse affects on supply chain, first time quality at
customers engine plants, or warranty performance.
Resolved an intermittent failure mode of shorting in the Gen 4 ignition module housing by defining and
implementing a 1500 volt dielectric stress test at our supplier to detect near shorts in the insert molded lead
frame.
References
Mr. Mike Brown, Manufacturing Engineering Manager, Delphi Automotive Systems, 765-451-7337
Mr. Brett Benzenbower, Ignition Product Line Manager, Delphi Automotive Systems, 248-732-0539
Mr. Cole Buttry, Kokomo and Flint Site Engineering Manager, Delphi Automotive Systems 765-451-7548
Mr. Mario Soto, Ignition Product Engineering Manager, Delphi Automotive Systems, 915-612-7610