Summary

Experience

Senior Design Engineer, Body & Exterior Systems|Ford Motor Company

Dearborn, MIJun 2022Present

• Led the design and integration of exterior body panels for a next-generation electric SUV, achieving a 15% reduction in part count and a 7% weight saving.
• Optimized structural integrity using advanced FEA simulations (ANSYS, Abaqus), improving crashworthiness by 20% against stringent safety standards.
• Collaborated with manufacturing teams to implement Design for Manufacturability (DFM) principles, reducing tooling costs by $1.2M and assembly time by 8%.
• Managed a portfolio of 5+ CAD models and component designs, ensuring adherence to GD&T specifications and supplier deliverables for critical deadlines.
• Successfully resolved 15+ complex design challenges through root cause analysis and iterative prototyping, accelerating project timelines by an average of 3 weeks per issue.

Design Engineer, Chassis & Powertrain Integration|Magna International

Troy, MIJun 2020May 2022

• Designed and validated structural components for chassis sub-assemblies, resulting in a 10% improvement in torsional rigidity for a luxury sedan platform.
• Utilized CATIA V6 and Siemens NX for 3D modeling and surfacing, delivering 25+ detailed component designs that met performance and packaging requirements.
• Conducted extensive CAE simulations for stress, vibration, and fatigue analysis, identifying potential failure points and proposing design modifications that saved $500K in material costs.
• Supported supplier engagement, reviewing technical drawings and specifications to ensure component quality and compatibility, leading to a 98% first-pass yield.
• Implemented standardized design practices across 3 major projects, increasing design efficiency by 18% and reducing rework cycles.

Projects

Electric Vehicle Battery Pack Integration Design

Jan 2023Oct 2023

• Developed a modular battery pack housing design that improved thermal management efficiency by 25% and reduced assembly time by 15%.
• Performed structural analysis to ensure compliance with severe impact safety regulations, mitigating potential design failures early in the process.

Advanced Driver-Assistance Systems (ADAS) Sensor Housing

Jul 2022Dec 2022

• Designed and optimized sensor housings for multiple ADAS components, ensuring seamless integration into vehicle architecture while maintaining aesthetic appeal.
• Utilized CFD to analyze airflow and minimize drag coefficients around sensor placements, contributing to a 0.5% overall aerodynamic efficiency improvement.

Lightweight Interior Door Module Redesign

Mar 2021Nov 2021

• Redesigned an interior door module using advanced composite materials, achieving a 20% weight reduction compared to the previous design.
• Collaborated with ergonomics specialists to enhance user interface and accessibility features, resulting in a 10% improvement in customer satisfaction scores during internal testing.

Education

University of Michigan - Ann Arbor|Master of Science in Mechanical Engineering (Automotive Focus)

Ann Arbor, MISep 2018May 2020

• Completed thesis on "Advanced Lightweighting Strategies for Electric Vehicle Chassis," reducing target mass by 12% in simulation.
• Maintained a 3.9/4.0 GPA, specializing in vehicle dynamics and structural analysis.

Georgia Institute of Technology|Bachelor of Science in Mechanical Engineering

Atlanta, GASep 2014May 2018

• Graduated Cum Laude with a focus on product design and manufacturing processes.
• Awarded Dean's List honors for six consecutive semesters (Fall 2015 - Spring 2018).

Publications

Optimizing Vehicle Body Structure for Enhanced Pedestrian Safety through Advanced Simulation

Sep 2023Keiko Yamamoto, Dr. David Chen

Application of Topology Optimization in Automotive Lightweighting: A Case Study on Chassis Components

Mar 2020Keiko Yamamoto

Material Selection and Manufacturing Process Considerations for Sustainable Automotive Components

Jun 2021Keiko Yamamoto, Dr. Sarah Miller

Skills

CAD Software

CATIA V5/V6Siemens NXSolidWorksAutoCADPTC Creo

CAE & Analysis

ANSYS WorkbenchAbaqusLS-DYNAFEACFDMaterial Characterization

Manufacturing & Materials

Design for Manufacturing (DFM)Design for Assembly (DFA)Injection MoldingSheet Metal FormingComposite MaterialsAdditive Manufacturing

Technical Competencies

GD&TDFMEATolerance Stack-up AnalysisVehicle DynamicsStructural MechanicsAerodynamics

Project & Process Management

Product Lifecycle Management (PLM)Product Data Management (PDM)Agile/ScrumRequirements ManagementRisk Assessment