Completed the frontal and side crash analyses for Explorer, Taurus, Taurus-X, MKS and FLEX. Improved the upper body, underbody, front end, seat and closure designs in C520, U502, D471/D472, U387/U388, CD338, D219/D258 and P273 programs. Not only achieved attribute targets such as crash safety, durability and NVH requirements but also reduced weight and cost. Through my effort, I saved more than 8 lbs per vehicle and reduced 40 welds per vehicle or more than 1 million dollars per year considering the assembly and labor cost.
- Lead engineer for U387/U388 programs. Presented reports to upper management and coordinated several MCR and MDO projects and reduced weight and cost for the vehicle.
- Trouble-shooting at the Ford Chicago Stamping Plant. Proposed optimized correction plans to solve running problems. Developed a verification method to evaluate the buckling limit for roof panels during the handling process.
- Completed all sorts of vehicle/systems analyses (linear and nonlinear, static and dynamic) such as NCAP, IIHS ODB/SORB, FMVSS207/210,225, full body durability, outer panel oil-canning/dimpling, dash cowl fatigue, door drop off/sag, door rigidity etc.
- Trained a group of 8 engineers to quickly learn how to run FMVSS analysis using LS-DYNA. Taught and helped other engineers to debug their FEA models and running problems.