Stephen Virgilio

1816 Bonita Avenue

Mount Prospect, Illinois 60056
Telephone: (847) 977-6460
Email:
PROFILE
Design Engineering Professional with strong background and skills in CAD, plasti
cs, plastic welding, new product component and assembly designs, tools and fixtu
res, with focus on balancing cost and high quality. Strength in imagination and
diverse experience in industries, such as, but not limited to automotive, agricu
lture, consumer and large appliance generates innovation. Achieve organizational
strength and profitable growth by strong personable skills, concise communicati
on, teamwork and working effectively with all facets of an industry.
TOOLS
* CAD - 2D and 3D: Pro-E & Pro-E Wildfire (12K hrs.); SDRC (4K hrs.); ProCADAM /
CADAM (27K hrs.).
* Other: MS Office, MS Project, Webex, ISO 9000 Internal Auditor Certified, GD&T
, DFMEA, PFMEA, PPAP, APQP, TQM, design reviews, vibration/hotplate/ultrasonic w
elding machines and tools, rapid prototyping, measuring and testing equipment, m
anual drafting, machine and hand tools.
PROFESSIONAL EXPERIENCE
DUKANE INTELLIGENT ASSEMBLY SOLUTIONS, Saint Charles, Illinois July 2004 - Nov 2
008
Project Engineer: Full project management, from feasibility to follow-up for 2D/
3D design of vibration, hotplate and ultrasonic weld tooling with actions - prim
arily for automotive OEM products. Global customer/vendor interface/travel. MS P
roject, Webex DRs and 2D/3D Pro-E Wildfire 3.0-some kinematics, BOM & tables.
ACCOMPLISHMENTS
* Tool orders increased 2-fold annually in my first 2 years, then 10-fold in fo
ur years.
* Outstanding solutions and successful first run trials for a multitude of majo
r accounts.
* Procured company's first ever tool order from my solo visit to client in Beij
ing, China.
* I was assigned to regain confidence and accounts from a large lost client. Af
ter 3 months I achieved all via flawless work.
* Presented weld processes and training at on-site seminars and off-site visits
.
ILLINOIS TOOL WORKS, FASTEX DIVISION, Des Plaines, Illinois Feb 2002 - Feb 2004
Project Engineer: Full project management, 3D design engineering and team leader
ship of new OEM product designs primarily for the large appliance industry. New
products of plastic injection molded, metal stamping, and wood. Also, progressiv
e dies and fixtures. Global customer/vendor interface/visits. MS Project, 2D/3D
Pro-E.
ACCOMPLISHMENTS
*
* Key accounts: Whirlpool, GE, and Electrolux.
* Patent: Dishwasher detergent dispenser.
* Certification: ISO 9000 Internal Auditor.
* Team: Innovations using electrically charged nickel-titanium memory shape wire
.
* Innovation: Outdoor grill igniter.
* Identified: $40K annual cost savings in mfg & raw materials.
* Design: Controls, plastic & metal fasteners.
CHERRY CORPORATION, Waukegan, Illinois May 1992 - Oct 2001
Senior Designer, Automotive Division (1994 - 2001): Temp hired as direct & promo
ted to Senior Designer in 1994. Full project management/design engineering, from
concept to follow-up of electro-mechanical automotive switch and trim programs.
Implementation of plastics, metals, woods, paints, coatings & rubbers. Also, to
ols, dies and fixtures. Global customer/vendor interface and visits. MS Project,
2D/3D CADAM, Pro-E & SDRC.
ACCOMPLISHMENTS
*
* Managed team to $230K annual savings through reduced rejects & trim mfg., cost
s.
* Design of Nissan Steering Wheel and Oldsmobile Memory Seat switches.
* $172K annual savings: Team - Improve quality and trim mfg of pins to PCB.
* Prepared competitive analysis for quality, cost, and pros/cons of competitor p
roducts.
* Simultaneous management/design of GM-Truck Platform Door and Seat Controls, wi
th continual visits to U.S & Canada GM plants.
* Led quality improvement team for Mitsubishi Mirror and Dimmer switches.
* Conducted and participated in team building and collaborative workplace events
.
Designer / New Product Design, Electrical Products Division (Contract 1992 - 199
4): Performed 3D modeling, layout, and detail of switch components and assemblie
s.
ACCOMPLISHMENTS
* Worked exclusively with Harley-Davidson's Styling Director & CEO in the design
of the Harley-Davidson 1996 Handle Bar Controls. Emphasis on artistic impact an
d ergonomics for buttons and housings.
* Generated designs for Hil-Rom, Whirlpool, and Pitney-Bowes accounts for produc
t enhancements.
TRITON COLLEGE, River Grove, Illinois Aug 1987 - May 2001
CAD Instructor, Adjunct Faculty: Instructor for introduction and light advance l
evels of CAD technology, ranging from 10 to 30 students per class.
ACCOMPLISHMENTS
* Instruction and course design of Pro/E 2000i, CADAM, ProCADAM and Computervisi
on / Cadds 5.
* High ratings from student evaluations as concerned, informative and brought in
dustry to classroom.
GENERAL MOTORS, ELECTRO-MOTIVE DIVISION, McCook, Illinois Sep 1991 - Mar 1992
Designer (Contract / Temporary): Performed manual and 2D CAD design, layout, det
ail, BOM, and GD&T to analyze and facilitate design work orders for brake and ax
le castings, HVAC enclosures, wiring, and piping for various locomotives. 2D IBM
 CADAM
JI CASE - IH, Hinsdale, Illinois Aug 1988 - Aug 1991
Designer (Contract / Temporary): Design, detail, alpha builds and testing of agr
iculture equipment, such as tractors and combines. 2D/3D IBM CADAM, ProCADAM and
ComputerVision.
ACCOMPLISHMENTS
* Trust, positive attitude and advance skills lead to be chosen from 16 person C
AD pool to exclusively join the Tractor Cab Dept., to assist Project Engineers w
ith design/detail of the new Maxxum Tractor cab.
* Window layouts, side mirror asm, fab metal controls, flooring, and roof hatch.
Emphasis on ergonomics.
ESAB WELDING PRODUCTS, Chicago, IL Apr 1988 - Aug 1988
Draftsperson (Temporary): Manually drafted graphics, labels, electro-mechanical
components and assemblies for electric and gas welding equipment.
RELIABLE ELECTRIC, Franklin Park, IL Jun 1987 - Mar 1988
Draftsperson (Temporary): Component design, detail and assembly layout for telep
hone system field enclosures, underground Control Environmental Vaults, receptac
le connectors, and phone jack assemblies.
ACCOMPLISHMENTS
* Designed door hinges to allow field technicians 35% more access to field box i
nteriors.
* Offsite supervision of 5 draftspersons to complete engineering change notices.
PORTER EQUIPMENT COMPANY, Schiller Park, IL Jan 1987 - Jun 1987
Draftsperson (Temporary): Understanding of structural blueprints to produce manu
al drawing layouts for installation of brackets, tubing, and hardware for athlet
ic equipment to new and existing building structures.
EDIFICATION
Machine Tool Technology and CAD Technology
Training, workshops, and seminars [not limited to]:
* Demand Flow Technology
* Dynamic Process Control
* GD&T
* Collaborative Workplace
* Franklin Covey
* Plastics: GE Plastics and SME
* Project Management
* ISO and QS Certification
* DFMEA
* Design For Manufacturing