Jeffrey A. Johnson

Stamping Manufacturing Engineering Department

• Conduct studies to establish robust processes for seamless front-of-line and end-of-line operations for new parts.
• Developed CAE simulation process using LS-Dyna and Hyperworks to analyze part dropping on conveyor systems, correlating results with physical CMM data to ensure a dimensionally proper part.
• Validate blank pallets, part racks, and worker ergonomics for new programs.
• Provide plant support during stamping die sets.

• Completed a 3-year rotational program, gaining hands-on experience across six distinct manufacturing engineering teams.
• Developed knowledge in stamping, die automation, CAE modeling, high-voltage systems, and body construction, enhancing process efficiency and quality in automotive manufacturing.
  
  

• Developed a predictive method for detecting wrinkling in stamped panels by establishing wrinkling criteria based on AutoForm stamping simulations.
• Conducted a sheet metal thickness downgauge study on multiple F-150 panels to assess feasibility and potential cost savings.
• Gained hands-on experience in the stamping process, covering early feasibility analysis, die design, CAE validation, die construction, and tryout.
• Explored various tooling design techniques and modifications to enhance panel quality.

• Conducted quality assurance testing on various automotive grommet projects to ensure compliance with OEM specifications.
• Designed, modified, and created detailed drawings of automotive grommets and NVH components in CATIA V5 for integration into the Teamcenter Database.
• Gained experience in rapid prototyping, tooling feasibility design, rubber injection molding processes, CMM dimensional validation, and polymer/plastic material properties.