Donald A.

Vorwerk
25027 Sullivan Lane (248) 380-3895
Novi, MI. 48375-1413 dvf4d4ec@westpost.net
BACKGROUND SUMMARY
Results oriented engineer with extensive experience in product engineering and d
evelopment, with broad technical problem-solving and analytical skills.
- In-depth background in disc and drum brake design, testing,.and brake lining
development.
- Patented simple wire ring design for retaining actuator mechanism in caliper
housing.
- Experience in truck steering and suspensions, design and testing.
- Experience with computerized data acquisition, noise and vibration analysis,
MS Project, MS Office, SolidWorks (Computer Aided Design), COSMOS (Finite Elemen
t Analysis)
- Experience preparing Design Validation Plans and Reports (DVP&R), Design Fail
ure Modes and Effects
Analysis (DFMEA), 8-D (design problem solving)
- Experience with Minitab and Weibull Statistical Analysis
- Management/Supervisory : Management by Objectives; Total Quality Management/T
otal Quality Leadership; project/budget preparation, tracking, and analysis; per
formance appraisals
- Certified in Six Sigma (Green-Belt)
- Certified as BAE Life Cycle Management (LCM) - Assessor for Design Reviews
PROFESSIONAL EXPERIENCE
BAE Systems Inc., , US Combat Systems, Sterling Hts., MI, (June, 2009 to No
vember, 2010)
Staff Mechanical Engineer - Mobility Engineering Responsible for technical dire
ction for brakes, pneumatics, steering, and suspension for the Joint Light Tacti
cal Vehicle (JLTV), proposed replacement for the military High Mobility Multi-pu
rpose Wheeled Vehicle.(HMMWV- Humvee)
- Designed and developed a right-hand drive brake system for the JLTV, for use
by the Australian military
- Participated in development of Brake Design Manual for Wheeled Vehicles.
- Prepared design proposal for JLTV brake controls, converting from a hydraulic
servo actuation system, to an air-hydraulic actuation system, using commerciall
y available, air brake valves and components to reduce cost.
- Participated in LCM Level 5 design review of MMPV vehicle program; specifical
ly the brake system.
TRW Automotive, Foundation Brake Engineering, Livonia, MI., (1997 to 2008)
Sr. Technical Specialist - Disc Brakes Provided technical leadership for major
brake design projects.
- Developed and validated front and rear disc brakes for passenger cars and min
ivans.
- Analyzed vehicle braking system requirements; created caliper and adapter bra
cket designs to fit space constraints.
- Developed test plans and fixturing. Managed test validation program from pro
totypes through production samples.
- Analyzed and presented test results to customer engineers.
- Wrote new test procedures for dynamometer and brake labs.
- Participated in Value Analysis/Value Engineering/Lean Manufacturing Events at
plants in USA, Brazil, and Mexico.
- Provided engineering support for products in production, such as calipers use
d on military AMGeneral Humvee.
- Lead engineer for design and development of rear integral parking brake calip
ers for Chrysler 2008 minivans (Chrysler Town & Country / Dodge Grand Carava
n / VW Routan) and CUV (Dodge Journey).
- Redesigned and validated rear integral parking brake caliper for 2004 Ford mi
nivans (Freestar/Monterey). Reduced weight, cost, and brake drag Improved ef
ficiency of park brake mechanism 15% to get higher output.
- Developed and validated newer style front caliper assembly for 2001 Chrysler
minivan. Design used as example for other applications such as Pontiac (Aztek)
and Buick (Rendezvous) CUVs.
- Worked with Purchasing to find and validate lower cost suppliers for AMG Humv
ee brake parts.
Lucas Industries, Heavy Duty Brake Systems, Troy MI., (1995 to 1997)
Staff Engineer - Disc Brakes Adaptation of current air and hydraulic disc brake
s to North American commercial vehicles; lining evaluation and selection; rotor
evaluation and design approval; lab and vehicle testing of prototype brakes, lin
ings and rotors. Validated disc brake design and installation for MCI J4500 Tou
ring Coach.
- Improved dynamometer wear test procedure for heavy duty disc brakes to aid in
lining selection.
- Developed improved rotor design to reduce thermal distortion during long down
hill descents.
Honeywell Corporation, Friction Materials Div., Troy, MI., (1992 to 1995)
Sr. Application Engineer Responsible for medium/heavy truck, GM passenger car
and light truck linings;
- Adapted heavy-duty truck disc brake lining to Chevy Caprice police car; to im
prove durability and performance.
- Prepared DVP&R to verify lining performance, durability, after pocessing equi
pment was moved to new FL plant
- Solved lining attachment problem on school bus lining, using Design of Experi
ments method, to isolate root cause.
BENDIX Heavy Vehicle Systems, AlliedSignal Inc., Elyria, OH. (1979 to 1991)
Project Engineer (1986 to 1991) Supervised application engineering group for tr
uck power steering and air s-cam drum brakes.
- Staffed and equipped facility to perform lab and vehicle steering analysis fo
r steering gears designed in Spain and manufactured in Brazil.
- Developed portable p/c data acquisition system for on-site vehicle steering a
nalysis and trouble shooting.
- Equipped a vehicle and demonstrated computer programmable truck steering syst
em that allowed changes in steering effort to be evaluated quickly by customer e
ngineers, reducing development time.
- Provided functional testing and warranty analysis on returned material, provi
ding information to customer more rapidly than when sent back to Spain for analy
sis.
Staff Engineer (1979 to 1986) Responsible for design, development, and validati
on of a new air actuated disc brake product line for trucks, busses and trailers
.
- Developed simpler, lower cost, more adaptable design of air-actuated disc bra
ke for commercial vehicles.
- Developed unique rotor design to minimize thermal distortion and heat-induced
stress, increasing disc life 1000%.
- Patented wire ring design for reliably retaining actuator mechanism in calipe
r housing (U. S. Patent 4503948)
- Created brake development program tasks and timing, technical specifications,
 performance requirements, and test procedures.
EATON Corporation-Brake Division, Southfield, MI. (1974 to 1979)
Engineering Supervisor Responsible for sustaining engineering for S-cam drum b
rakes, off-highway steering axles and trailer axle product line.
- Developed low cost stamped steel torque spider for drive axle brakes, to repl
ace machined cast part.
- Developed dynamometer lab test procedures; improved accuracy of data collecti
on and reduced test variability.
- Developed product validation program for verifying compliance to FMVSS-121 dy
namometer requirements.
EDUCATION
B.S.- Engineering - Major in Mechanical Design, Case-Western Reserve University,
Cleveland, OH 1967
Graduate Courses and Professional Seminars:
Kinematics of Linkages - Case-Western Reserve University 1971
Design of Weldments - Lincoln Electric, Cleveland, OH 1972
Problem Solving/Decision Making - Kepner-Tregoe, 1976
Design Against Fatigue - Eaton Corporate Research Center 1977
Allied Engineering Update - U of Mich, Ann Arbor, MI 1986
Statistical Methods & Controls - Bendix Corp.Research Ctr 1987
Spanish (begin & interm)- AlliedSignal (in-house classes) 1991
SolidWorks CAD System - Fisher/Unitech, Troy, MI 2003
Six Sigma - Green Belt - TRW Automotive 2006
Project Mangement I & II- Walsh College, Troy, MI 2008
Professional Societies: Society of Automotive Engineers - Member
Chairman - SAE - Cleveland Section 1985/86
Delegate - National Nominating Committee 1987 to 1991
Member - Brake Technical Committees 1979 to 1997