Engineering Manager- Driveline Innovation @ Magna Powertrain
Engineering Manager @ Hendrickson
Engineering Manager @ NTN Bearing Corporation
BSME, Engineering @
Western Michigan University
Engineering Manager- Driveline Innovation @ Manage the reasearch and technology group From October 2014 to Present (1 year 3 months) Engineering Manager @ Managed the military and rescue group of Hendrickson international which consisted of project engineers, project managers, simulation/FEA engineers, and design engineers. Lead the engineering group with a high level of ambiguity based on both
Engineering Manager- Driveline Innovation @ Manage the reasearch and technology group From October 2014 to Present (1 year 3 months) Engineering Manager @ Managed the military and rescue group of Hendrickson international which consisted of project engineers, project managers, simulation/FEA engineers, and design engineers. Lead the engineering group with a high level of ambiguity based on both green sheet designs with minimal information provided from customers. Headed all technical development and integration into our manufacturing facilities. Significant work with suppliers for new technologies based on an ultra-high pressure air suspension.
• Created and monitored technical standards/specifications for driveline configuration and sizing for all independent suspensions.
• Managed full design and integration of independent suspensions and drivelines for multiple military, crane, coach, and rescue applications.
• Lead vehicle design of chassis and driveline for Navistar NSTT and Hardwire ULV truck
• Designed new fabricated differential for a low cost independent suspension project in India.
• Designed, quoted, and tested (pending) a new ultra high pressure air suspension; including manifold, solenoids, ECU, compressor, and system strategy. Multiple patents submitted.
• Managed customer interface, component design, and validation plans for all military and special truck projects
• Team handles all design attributes of the independent suspension including; Struts, springs, structures, driveline, and bearings.
• Gained exposure in truckSIM for suspension kinematic design, NX 9.3, and Teamcenter 9.1 for model/print review and release. From June 2012 to October 2014 (2 years 5 months) Engineering Manager @ Manage a team of 12 engineers overseeing all driveline engineering functions including; product engineering, application engineering, and test engineering. Responsible for negotiating program specifications throughout development including; product design, bench testing, and vehicle testing. My team is also in charge of global program management, quality issue resolution, and warranty analysis. Create and handle all budgetary aspects of engineering group including R & D, travel, and extraordinary items. Promote continuous improvement with workforce collaboration.
• Demonstrated efficient issue resolution on 8 key quality problems in 2011. Swift and decisive action under rigorous customer demands were essential to success.
• Developed new hybrid laser welding process on new tubular longstem halfshafts. Process decreased manufacture costs while increasing part performance and market competitiveness.
• Under cost pressure from competition, was able to optimize design with global coordination and reduce manufacturing costs by 20% - 30% through changes in suppliers, methods, and metal forming processes Patent #8,613,556
• Successfully obtained and launched $160 million in new Ford, Honda, GM, Mazda and Toyota business in 2011. Programs met customer milestones throughout product lifecycle and launched on-time.
• Effectively reduced cost by 9% and increased profit by 5% in FY 2010 through VAVE and warranty reductions
• Leading development of new low cost hollow I/C shaft by changing the forming process method. The target for this project is a 40% reduction in manufacturing cost.
• Currently leading multiple innovation and development projects for automotive and emerging industrial based constant velocity joint systems. Patent# 9,028,332. From November 2001 to May 2012 (10 years 7 months) Application Engineer @ Managed multiple propshaft and halfshaft programs from inception, through the programs lifecycle, continuing engineering support into production. Responsibilities included design, technical support, development of test specifications, and manufacturing plant support. Satisfied design requirements through incorporation of extensive background in GD&T and machining capabilities. Developed DVP&R, DFMEA, and program Gantt chart to meet customer milestones.
• Designed and developed new constant velocity joint venting system for 3 piece propshaft
• Determined root cause of halfshaft spline failure to be sealing system. Redesigned stamped seal assembly using FEA to calculate maximum stress and deflection during installation.
• Lead simultaneous design team for new Chrysler Pacifica and Dodge DR propshaft programs. Process included program management function and design optimization for manufacturing.
• Worked closely with manufacturing plant to ensure successful launch of new three piece propshaft. From 1999 to 2001 (2 years) Metallurgist @ Maintained process and quality conditions for the carburization furnaces and induction hardening units to promote manufacturing quality. Technical evaluation of gas metal arc, friction, and magnetic arc welding of steel, aluminum, and metal matrix composites leading to the resolution of welding issues. Analyzed heat treatment and microstructure in castings, forgings, and cold drawn tubing. Updated and maintained assembly plant tooling and machinery.
• Developed friction welding process to replace gas metal arc welding in aluminum propshafts.
• Implemented process changes in aluminum propshaft departments which decreased scrap by 12%
• Engineered secondary attachment method for balance weights on aluminum and MMC propshafts.
• Created and implemented new heat treat process control method for carburization furnaces.
• Optimized propshaft balance procedure to increase throughput by 15%, thus reducing manufacturing cost. From 1996 to 1998 (2 years)
MEM, Engineering Management @ Penn State University From 2011 to 2012 BSME, Engineering @ Western Michigan University From 1995 to 1998 Brad Ketchel is skilled in: APQP, Engineering, PPAP, Manufacturing, Lean Manufacturing, Continuous Improvement, Bearings, GD&T, Automotive, Root Cause Analysis, SPC, DFMEA, DVP, Engineering Management, Manufacturing Engineering, Pro Engineer, Geometric Dimensioning & Tolerancing, FMEA
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