Presentation: Project Management in Formula SAE

Biography: Emily Anthony is currently a Mechanical Design Engineer at FAAC Incorporated and a student in the Masters of Mechatronics Systems Engineering program at Oakland University.

Emily has a BS in Mechanical Engineering from the University of Pittsburgh and focused in Biomechanics. As a student, Emily was active in Formula SAE for 4 years and was the team captain of the 2016 team. After graduation, Emily continues to be involved in the program as an SES reviewer, technical inspector, and a Cost Auditor. In addition, Emily organizes the Pittsburgh Shootout autocross at Pittsburgh International Race Complex.

Abstract: This lecture is intended for current Formula SAE students who wish to improve upon their project management concepts. This lecture is appropriate for both new members to team captains and is presented in a fashion that is easy to understand without prior project management knowledge. Each section will focus on changing how the team thinks about project management problems with examples from Emily’s experience in Formula SAE and industry and provide questions for student leaders as a starting point for discussion and improvement. Students will learn how to perform FMEA, build a gantt chart, generate lessons learned documentation, and more.

Discussions include:

• Integration and Scope
• Time management
• Risk management

Restrictions: None

Presentation: Vehicle Dynamic Testing for Formula SAE: Utilizing vehicle dynamic testing for design

Biography: Siddarth 'Sid' Attravanam is currently a systems engineer with SpaceX focusing flight hardware and concepts-of-operations leading to successful completion of missions while meeting or exceeding design requirements. Sid was also engineering manager with Cooper Tire & Rubber Company in the field of vehicle dynamics with the primary area of research being in understanding the links between human perception of driving and objective measurements of vehicle and tire dynamics. As part of this, he has led the development of new objective and subjective vehicle testing methods. Sid has also co-developed and teaches a training program for Cooper that teaches engineers the basics of vehicle/tire dynamics along with subjective evaluation.
Outside of Cooper, Sid is a technical scrutineer with the FIA at the World Endurance Championship race at the Circuit of The Americas, Austin, TX. Sid is also active with the Formula SAE community, having worked with Cooper to re-enter the Formula SAE competition as a sponsor, and through the Tire Test Consortium. In addition, Sid is also a design judge specializing in Suspension/Tires at both Formula SAE Michigan and Lincoln competitions.

Abstract: For many Formula SAE teams, vehicle testing ends up as an afterthought. In the testing that does happen, the idea of whether the car is driveable or controllable is usually lost in the myriad of reliability testing. So while reliability is critical, the vehicle also has to be designed to be operable by a human driver. Similar to how factors of safety are design goals for reliability, handling goals can also be design goals. This presentation will cover fundamentals of vehicle handling related to human perception, simple testing procedures such as skidpad and slalom, and use of data from vehicle testing and tire testing to tune handling of the current car and set design goals for future cars. The presentation will also cover some simple simulation tools that can be used to quickly evaluate high level handling design goals. Finally, the presentation will address using a 'systems engineering process' to plan vehicle design.

*Get an idea of Sid’s condensed presentation on vehicle dynamic testing here, presented at COMVEC 2019.

Restrictions: Available any weekday. Weekend could also be accommodated. Please provide request 4-5 weeks in advance.

Presentation: The Business of Motorsports, The Politics of Alternative Fuels, Notes for Aspiring Engineers : 30 Years of Lessons Learned

Biography: Dean Case has been an active SAE member since his freshman year at Cal Poly San Luis Obispo in 1981. He grew up in a motorsports family and progressed from race fan as a kid, to automotive engineer as an adult. He has devoted the past 15 years of his professional career to automotive communications with an emphasis on motorsports and technology PR, and an interesting inclusion of non-profit partnerships.

Within SAE, Case was a student leader, including being an SAE-sponsored WISE intern. He served as a board member with both the SoCal and Detroit Sections. He has been a Distinguished Younger Member, awarded a FISITA Young Engineer Fellowship, sponsored over 50 new SAE members, served on multiple SAE International committees, published two SAE papers, and spoken at dozens of universities over 30 years, 14 of them in the most recent 2016-17 school year.

After graduation from Cal Poly, Case started his professional career with Mazda R&D in Irvine, CA. While at Mazda he worked on the original Miata, second-generation MX-6, first-gen MPV, and third-gen RX-7.

After seven years with Mazda he joined Ford in Michigan as a layout engineer in the electric vehicle department before transferring to Ford Motorsports. While the Ford experience was professionally rewarding, Case wished to return home to Southern California. That move came in 1998 when he joined Nissan as a Product Investigation Engineer where he fell back into the EV world, being one of the lead American engineers on the Nissan Altra EV, and Nissan Hypermini EV programs, the predecessors to the Nissan Leaf.

Case was acting as the EV technical expert on a Nissan media event in 2000, which led to his career change from engineering to communications. Case became the Nissan Product PR Manager in 2001 and retained that position until 2006. In 2006, when Nissan relocated its U.S. headquarters to Nashville, TN, Case began a freelance consulting career.

His first client in 2006 was SAE International, managing the first two Formula SAE West competitions.

Case was then reunited with Mazda, becoming the Communications Officer for Mazda Motorsports in 2006. He spent the next 11 years on the road promoting the Zoom-Zoom nation from the SCCA Runoffs to Le Mans.

He is currently a consultant to Motivo Engineering and Grassroots Motorsports Magazine. Motivo is a product engineering company noted for efficiently turning complex ideas into clever products. Dean met the Motivo engineers via Formula SAE, so it was a great fit.

Case has been an active volunteer with SAE, the Motor Press Guild, Friends of Torrance Animals, PAWS/LA, and the Motorsports Hall of Fame over the years.

Abstract: Graduating engineers today have more technical skills than ever before, but many have minimal comprehension of what life in the real world is like. Dean shares lessons learned that were not included in his BSME education. He will cover how to leverage active SAE participation into career opportunities, the good, bad, and ugly aspects of modern professional motorsports, and the ever changing politics of alternative fuels. Dean has given this presentation to over two-dozen times to schools from across the country. His presentation is designed to motivate first and second year students to become more involved with SAE. He welcomes a lively Q&A session.

*Preview Dean’s presentation, where he presented a shortened version of his lecture at WCX 2019.

Restrictions: No set restrictions - however, certain obligations might arise between now and when a lecture is requested, so some scheduling flexibility may be necessary. Ideally one-month lead is requested. Working with the local SAE section is encouraged such that a second nearby school might also be scheduled.

Presentation: Formula SAE, A Design Judge's Perspective

Biography: Steve currently heads an innovative manufacturing company, specializing in lightweight low-inertia drivetrain products for motorsports. In addition to 'off the shelf' solutions, he oversees one-off engineered drivetrain solutions for industrial and street use.

Previously, Steve was Engineering Director for Quarter Master Industries, Inc. (QMI), where he was employed for two decades. Steve is well versed in manufacturing engineering and materials selection and served as a design engineer responsible for all new product design, development and manufacture for most of his tenure with QMI, while at the same time dealing with many of the top racing teams from around the world.

Steve is an expert in I.C. engine technology and power transmission. One notable example of his development capability is the drivetrain package for Dodge's return to NASCAR in 1999. With a motorsports career that spans nearly 40 years, He has engineered, constructed, wrenched on, driven, broken, or piloted almost everything imaginable with 2, 3 or 4 wheels, a hull, or wings. He is a licensed aircraft pilot, racecar driver, scuba diver, and firearms instructor.

Steve was selected by Carroll Smith to participate in Formula SAE (FSAE) as a Motorsports Design Judge in 1999. He has been giving back to future engineers with FSAE involvement ever since. He has judged Baja SAE events, served as the Design Event Captain at FSAE - Virginia, and Chief Design Judge at Formula Student Austria. Steve is currently the Chief Design Judge for FSAE - Michigan, and also serves as Chief Design Judge at Formula Student Germany.

Abstract: Steve's presentation 'Those Who Cannot Remember The Past Are Condemned To Repeat It' is specifically targeted towards FSAE teams who wish to build a better car, without re-inventing the wheel. This presentation can be adjusted to suit the experience level of each team being visited. Historically, FSAE championship-winning teams, as well as new teams, have benefited from his presentations.

Subjects that Steve will cover include: Vehicle Design Principles; Chassis; Suspension; Steering; Brakes; Engine; Drivetrain; Gearing; Ergonomics; Team Management; Manufacturing; DFM (Design For Manufacturability); Material Selection; Heat Treat; Testing; Points Strategy Considerations; and most importantly, Project Management. Steve covers a LOT of material. Many teams video or audio record these meetings for review later.

After his formal presentation, your team may present your efforts to date. He will help you evaluate your design choices, and offer advice on selected optimization techniques. The informal question and answer session which follows can cover any area of FSAE competition. Your team's efforts are treated in the strictest of confidence. Steve will not share ANY information between schools.

Please understand Steve does not give your team 'the answers to the test'. He has to remain unbiased in order to be able to fairly and impartially judge at the competitions. He does provide insight and ideas from a design judge's perspective. Most importantly, he offers methods for 'thinking outside the box' that have driven past teams to new heights.

Restrictions: Friday evenings, Saturdays (or Sundays) are preferred, but weekdays can sometimes be accommodated.

Presentation: Autonomous Vehicles: The Role of HIL (Hardware-in-the-Loop) Simulation in Testing Ford's Autonomous Vehicle Platform

Biography: Mr. Adit Joshi is currently working as a Research Engineer in the Controls and Automated Systems department at Ford Motor Company. His current responsibilities include supporting the hardware-in-the-loop (HIL) simulation of Ford’s Autonomous Vehicle Platform alongside supporting other CAE simulation activities for electrification, mobility and connectivity.

Mr. Joshi’s previous experience includes working as a HIL Engineering Specialist at General Motors. Before joining automotive industry, Mr. Joshi graduated with a Master of Science in Mechanical Engineering specializing in Vehicle Dynamics and Controls, and a Bachelor of Science in Electrical Engineering specializing in Controls, both from The Ohio State University.

He has authored six SAE technical papers and one SAE journal article on HIL simulation. He also volunteers as a lecturer for the SAE Industrial Lecture Program and serves as a peer reviewer for the SAE International Journal of Connected and Automated Vehicles. He serves as an SAE Company Ambassador at Ford and is also active in the Ford campus recruiting team for The Ohio State University.

Abstract: The automotive industry is heading towards the path of autonomy with the development of autonomous vehicles. This presentation will provide an overview of autonomous vehicles and discuss why there is an urgent need for this technology. It will also focus on the requirement of redundant mechanical systems and controls as part of the autonomous vehicle platform since there will be no driver backup present in highly automated vehicles. This presentation will elaborate on the role of simulation in accelerating development and testing of autonomous vehicles as in-vehicle testing for autonomous vehicles will be considered expensive, time-consuming, and unsafe due to the number of scenarios and driven kilometers required for validation. In particular, a powertrain and chassis hardware-in-the-loop (HIL) simulation of the autonomous vehicle platform and the correlation of the performance of the corresponding subsystems with those of the actual autonomous vehicle will be presented. The testing setup for HIL simulation which includes powertrain controllers and actuators, redundant brakes and steering controllers, alongside full brake hydraulics hardware will be discussed in detail.

Restrictions: Request at least two week notice to fit into work schedule

Presentation: Tire Testing and Modeling for Vehicle Dynamics

Biography: Dr. Kasprzak is the President of EMK Vehicle Dynamics LLC and an Associate at Milliken Research Associates Inc. He has worked in the field of automobile vehicle dynamics since 1996 with expertise in the areas of tire & vehicle testing, modeling and simulation. Customers have included passenger car manufacturers, their suppliers and professional racing teams. Kasprzak is the co-founder and co-director of the Formula SAE Tire Test Consortium and annually serves as a design judge at North American Formula SAE events. He is a former Adjunct Assistant Professor at the University at Buffalo where he taught two courses on vehicle dynamics and advised the SAE student chapter. His publications include numerous technical papers, magazine articles and co-authorship of "Race Car Vehicle Dynamics: Problems, Answers and Experiments" with Bill and Doug Milliken. He also contributed several chapters to "Learn & Compete: A Primer for Formula SAE, Formula Student and Formula Hybrid Teams". Kasprzak is the 2012 recipient of SAE's Excellence in Engineering Education award.

Abstract: This lecture will focus on tire performance as it relates to vehicle dynamics. It will include a brief overview of tire construction, a discussion of laboratory tire testing, a discussion of tire model development from measured data, and the application of tire models to vehicle analysis, design and simulation.

Restrictions: None; allow time to discuss your car/team in your shop in addition to the lecture.

Presentation: Biomimicry: Sustainable Designs Inspired by Nature

Biography: Amanda is a senior polymer engineer with eight years of experience in the automotive industry. She graduated from Georgia Tech with a Bachelor's of Science in Polymer, Textile, and Fiber Engineering, and holds a Master's degree in Materials Science and Engineering from Wayne State University. She is currently pursuing postgraduate studies in Biomimicry through Arizona State University. Amanda works at the Hyundai-Kia Technical Center just outside of Ann Arbor, Michigan. In her current role, she is responsible for plant support and new application development of all plastic components for North and South America. Previously, she has worked on research and product development for hydrogen fuel cells, biomedical devices, specialty textiles, nanomaterials and quantum computing. She has an interest in alternative energy, sustainability, and the prevention of plastic waste in the oceans. Amanda has presented several times at the SAE World Congress, and is excited to join the SAE Industrial Lecturer program.

Abstract: Nature has been solving problems and refining solutions for 3.8 billion years. Humans can leverage the vast knowledge of nature as a model to design efficient and sustainable products, infrastructure, and processes. This methodology can be useful for students and professionals across a variety of industries. The lecture will cover the following key points:

• What is biomimicry
• How and why we can use it
• The benefits of multi-disciplinary design teams
• Case studies of biological strategies emulated in biomimetic applications 
• A short brainstorming or scoping activity
• Several resources and tools to add to your design thinking

Restrictions: 3-4 weeks notice preferred

Presentation: Racing Brake Systems – Understanding FSAE Design Judging – Effective FSAE Team Organization and Planning

Biography: Mike O’Neil has earned his living in professional motorsports since 1995 and has been involved with Formula SAE even longer. As a student, he competed in FSAE for four years at the University of Akron, where he received his BS and MS mechanical engineering. He was on a first-year team, team captain for three years, and was an adviser while in graduate school. Fellow industry professional Carroll Smith recruited him for design judging, for which he was the Chief Design Judge for all FSAE California events. O’Neil was Technical Director for Tilton Engineering Inc. for 14 years and has been Technical Director for Essex Parts Services Inc. since 2010. His technical areas of expertise include brake, clutch, and driver control systems. He is in charge of all new-product development, designed the brake system dynamometer, and is in charge of all brake system testing at Essex. He also designed the brake bedding machine for which he holds a patent. During his career, he has worked with NASCAR, Indycar, professional sportscar, off-road, and other teams with their brake and driveline systems. As one who builds and races his own machines, he was a 2009 AMA flat track motorcycle amateur champion. He is still active on the amateur national level.

Abstract: The presentation is multi-faceted, covering the needs of different team members. Almost all students express the need for better team organization and planning. Most also want to know more about how their program can help them to be more successful in the Design scoring category, which can also help them in all areas of performance. Then there is the brake system, which is more powerful than the engine. Yet, it is an area that most SAE teams do not address to near its full potential. The presentation does not get into the math as much as it does explain how the brake system works, the important details that are often unknown or missed, and what to consider when designing the brake system. One needs this understanding before one can properly use the equations and develop a top-notch system.

Presentation: Paradigm Shifts in Transportation Architecture and The Role Of Lightweight Design

Biography: Mr. Peterson is an automotive engineer who worked at Pontiac Product Engineering, CPC (Chevrolet-Pontiac-Canada group) Advanced Vehicle Engineering, DaimlerChrysler SRT (Street and Racing Technology) and Lotus Engineering, the US division of Lotus Cars UK. He also raced a Formula Vee and was part of Herb Adams’ NASCAR (Pontiac Grand Am) race team.

He holds fourteen patents in multi-disciplinary fields and has been published by the Society of Automotive Engineers, IMechE, the International Appliance Technical Conference and Purdue University as well as numerous magazines. He has written and presented over 50 technical studies and is a regular speaker and chairman at national and international engineering conferences. He has been a keynote speaker for multiple organizations, including NASA.

He has had experience in virtually all vehicle systems, including EV architectures, and has held a wide variety of engineering positions including Development Engineer, Senior Technical Specialist, Assistant Staff Engineer, Director of Engineering and Vice President.

He led the Lotus 2025 fuel economy study, funded by ARB, the California Air Resources Board, that documented that a 30% lighter vehicle could be as safe as heavier vehicles, provide substantially improved fuel economy and be built at near cost parity relative to heavier, all steel vehicles. This study was used by the federal government to assist in setting the original 2025 fuel economy standards. Mr. Peterson made multiple presentations of this peer reviewed study to government agencies, including NHTSA and the EPA.

Abstract: There are multiple paradigm shifts occurring that impact the transportation industry: 1. The transition to substantially more energy efficient vehicles; 2. The change from human control to machine control; and 3. The expanding development of personal 3D transportation modules that replace 2D based vehicles.

This presentation addresses each of these areas using production examples, where appropriate. It verifies relevant postulations using math models derived from first principles and includes a discussion of the fundamental physics that engineers must consider when designing safe and efficient vehicles.

The presentation will assess the specific contributions of enabling technologies, including aerodynamics, mass reduction and tire/wheel/chassis systems. Example cases, based on Lotus public domain projects, will be cited to demonstrate the potential for improving vehicle energy efficiency. The review will cover the ground up design of a lightweight vehicle that weighs 30% less than the identical size steel baseline vehicle; the body structure is almost 40% lighter than the baseline steel vehicle. Key systems will be reviewed in detail including the body structure, chassis/suspension, interior and closures. The structural performance of this vehicle will be reviewed. Animated models undergoing FMVSS crash testing will be shown and compared to NHTSA test results for the baseline vehicle.

This is an interactive presentation; the author typically asks the audience numerous questions meant to challenge participants.

Restrictions: Request 3 weeks advance notice to fit into work schedule

Presentation: Defects in Aircraft Design & Materials: Engineering Lessons Learned

Biography: Larry Rinek is the Principal Consultant at Rinek Consulting Services. He was formerly a Senior Technology Consultant in the Technical Insights Division of Frost & Sullivan, where he had more than 17 years of service. His focus there was evaluation of emerging technologies and their commercial potential in aerospace & defense, automotive & transportation, industrial machinery, as well as advanced engineered materials. He is a trained engineer, a published historian (author of more than 25 items, including 6 SAE publications) focusing heavily on U.S. aviation technology history, a former USAF officer, a former student pilot, and veteran of the U.S. aerospace industry. Mr. Rinek is an active member of the AIAA and SAE technical societies, as well as the American Aviation Historical Society (AAHS), the Aircraft Engine Historical Society (AEHS), the Society for Aviation History (SAH), and the Wings of History (WOH). He earned a BS (with honors) in Industrial Engineering and an MBA in Marketing, both from UCLA. He has also been a guest lecturer in aero engineering for 9 colleges and universities across the US and Canada, with most of these visits sponsored by the SAE. Mr. Rinek has over 40 years of business and technology consulting experience. Many of his consulting projects have been sponsored by leading aerospace and motor vehicle builders/system suppliers around the world.

Abstract: Why have preventable mishaps in aircraft occurred (which are not the fault of pilots), resulting in loss of life and property? Many of these incidents are directly attributed to human error and negligence in aircraft design as well as processing of materials (manufacturing issues). How can engineers prevent or at least minimize such unpleasant events, thus improving aircraft safety? What lessons can we learn from historical mishaps, so that they might be avoided in the future? Answers to these questions will be addressed, while exploring 12 case studies, involving some well-known civil and military aircraft programs. We will see how engineers recovered from hidden defects, and developed workable solutions.

Restrictions: Request a few weeks advance notice, to fit into work schedule

Presentations & Abstracts:

1. Lamborghini Engineering—Chrysler's Foray into Formula 1
   In 1987, Chrysler purchased Automobili Lamborghini S.p.A. and decided to design and build a Formula 1 engine for sale to F1 teams. They formed a new company, Lamborghini Engineering S.p.A. for this purpose. This presentation covers the history of Lamborghini Engineering from its birth until its demise in 1994, when it was sold to an Indonesian consortium, focusing on Mr. Royce's time in Italy as the Technical Director from November 1991 to May 1994.

2. Detroit to Austin—A Look at 35 Years of Formula 1 in the USA
   This presentation looks at 35-plus years of Formula 1 in the USA from Royce's perspective as a scrutineer (technical and safety inspector) at the Detroit, Phoenix, Indianapolis, and Austin events from 1982 to the present, and highlights some of the changes that have occurred in that time. This presentation is usually given with his wife, Suzanne Royce, who has been the Chief Scrutineer for Formula 1 in the U.S. since 1985. Suzanne Royce is the only female Chief Scrutineer in Formula 1 today.

3. Grades Do Count-But That's not All—Tips for Engineers in Training
   Good grades and technical skills are not all that employers are seeking. Based on his forty years in the automotive industry, Michael Royce will review the other attributes and skills that employers are seeking in their new hires, and how programs like the SAE's Collegiate Design Series can supply a number of these attributes. He will also suggest some tips when preparing for job interviews and give his thoughts about continuing education.

A number of presentations pertaining to Formula SAE and Formula Hybrid, specifically:

• Team Building & Organization
• Project Management
• The Design Process
• Safety
• Sponsorship
• The Frame & SES
• Testing & Development
• Report Writing & the Reports
• Traveling To and At the Competition
• Getting Through Technical Inspection
• Resources

Biography: Michael Royce, now working as a consultant for Albion Associates LLC, retired from the DaimlerChrysler Corp. in June 2004 after almost 41 years within the Chrysler family. During that time, he held a number of management positions, including assignments in Truck Engineering, Product Planning, Engine Development and Powertrain Program Management. Between late 1991 and 1994 he was the Technical Director at Lamborghini Engineering in Italy, managing the Chrysler-Lamborghini Formula 1 engine program. His last assignment at Chrysler was that of Senior Manager of Advanced Engine Technologies & USCAR Programs.

He has been an active member of SAE International since 1965, served on the organizing committee of all the SAE Motorsport Engineering Conferences and is a long-standing member of the Motorsports Engineering Committee. From SAE, he received the Excellence in Engineering Education Award in 2005 and the Forest R. McFarland Award in 2010.

Royce has been actively involved in Formula SAE since 1986, was a member of the Formula SAE Rules Committee from 1996 to 2009, its Chairman from 2000 to 2009 and Chairman of the University Programs Committee from 2004 through 2007. He is currently on the Rules Committee for Formula Hybrid. He has officiated at over 80 Formula SAE, Formula Hybrid, Formula Student (UK), Formula SAE-Australasia and Formula SAE-Italy competitions. He, his wife Suzanne, and a number of other leading FSAE experts recently published the book "Learn & Compete, a Primer for Formula SAE, Formula Student and Formula Hybrid Teams."

He has been a licensed scrutineer (technical and safety inspector) since 1973, officiating at local SCCA autocrosses, club and pro races, stage rallies, FIA-GT, World Endurance Championship, Formula E, Moto GP and Formula 1 events. He has been the Assistant Chief Scrutineer at every Formula 1 Grand Prix in the USA since 1986.

Royce has master's degrees in Mechanical Sciences from the University of Cambridge, in Automotive Engineering from the Chrysler Institute of Engineering, and in Management from the University of Michigan-Dearborn.

Restrictions: None

Presentation: Why Care About Human Factors: A Case Study Approach

Biography: Ben Schwartz is a human factors engineer, systems engineer, and human-systems integrator. He has experience with a variety of complex commercial and military systems including helicopters, autonomous aircraft, and command and control systems. He currently provides consulting services through his company, System Solutions Research.

Ben is an INCOSE Certified Systems Engineering Professional (CSEP). He participates in the SAE committees G-45, Human Systems Integration, and G-47, Systems Engineering. He was a co-author of ANSI/HFES Standard 400-2021, Human Readiness Level Scale in the System Development Process. You can read his thoughtful analysis of current industry trends and events at engineeringforhumans.com.

Abstract: It doesn't matter how good a technology is if humans can't use it effectively to accomplish their goals. As technology capabilities advance rapidly, it is often the human in the loop that is the performance bottleneck. Worse, "human error" is often blamed for failures and accidents where the design of the system didn't effectively support the operator's performance.

This presentation takes a case study approach to engage a general technical audience. It analyzes three to six cases of failure with human factors design as a primary contributing factor with discussion of lessons for engineers that are applicable to any type of system and industry. The goal is to develop an appreciation for the importance of human factors engineering in the design of modern, complex systems.

Restrictions: None

Equipment Needs: Projector and slide remote

Presentation: Optimizing FSAE Designs using the best practices in CAD, FEA, and CFD

Biography: Jim Shaw is currently the Managing Director of Fastway Engineering, an engineering firm dedicated to helping companies get the most out of their CAD/CAE software. Using hands-on, project-based curriculum, Fastway Engineering helps Designers, Engineers, Makers, and Manufacturers climb up the learning curve as fast as possible. Prior to that, he's designed, analyzed, tested, built, and broken a wide range of products. LinkedIn profile

Abstract: This lecture is intended for current Formula SAE students who realize that in order to optimize your design, you need to try to as many design variations as possible. To do so, the use of Computer Aided Design and Engineering (CAD/CAE) tools, including Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) is required. These skills are not necessarily a part of the current academic curriculum, but they are almost certainly required by hiring companies. The Formula SAE program provides the perfect environment for establishing robust CAD/CAE practices.

This seminar does not focus on a single specific software package, but rather it addresses the benefits (and limitations) of the software as a whole, and attempts to establish methodologies that can be applied to any CAD/CAE software. Discussions and hands-on projects include:

• Best practices in CAD Design – from Part Geometry creation to Assembly Data Management
• Time-saving techniques for preparing CAD geometry
• An overview of meshing for FEA & CFD (Tet vs. Hex)
• Static vs. Dynamic FEA
• An overview of all commercially available CFD codes & Turbulence Models
• Turbulent Steady State Flow around an FSAE vehicle
• Calculating lift and drag from a CFD analysis
• Using digital design tools in the professional Product Development Process
• Pros & Cons of using local vs. remote services (Cloud Computing, SaaS, etc)
• Tube chassis: Design, analysis, testing, and manufacturing.
• FSAE Rules (Part T Article 3 & Part AF), SES form, etc.

Prior knowledge of 3D CAD/CAE tools is required. Each seminar can focus on which ever software the school wants, such as those from: Ansys , Autodesk, CD-Adapco, Dassault Systems (CATIA & Solidworks), Onshape, OpenFOAM, PTC, Siemens PLM, Simscale, etc.

Restrictions: None

Presentation: The Adventures (and Misadventures) of a Lubricant Engineer: Fun with Oil

Biography: Smolenski has a B.S. in Chemistry from the University of Michigan–Dearborn and a Ph.D. in Chemical Engineering from Wayne State University. He has formed and is president of a consulting firm, Strategic Management of Oil, LLC. Previously, he was OEM Liaison Manager - North America, Evonik Oil Additives USA; responsible for OEM contacts and management of fuel economy projects. Smolenski retired from GM after a 33-year career spanning R&D and Worldwide Facilities. He developed and ran engine dynamometer and field tests, is a co-inventor of the GM Engine Oil Life Monitor installed in nearly all GM North America vehicles since 2000, developed GM industrial lubricant standards and lead the GM used oil management and recycling program, championing the use of recycled oil in plants. Smolenski is a Fellow of the Engineering Society of Detroit and SAE International. He jokes that he has 22 kids all over the world—19 were foreign exchange students.

Abstract: Dr. Smolenski's presentation will cover the more interesting anecdotes from different segments of his career. He will show how taxi tests helped elucidate the effects of subtle differences in antiwear chemistry on wear results. He will discuss how they gained deep insights into engine hardware (things that the engine guys didn't even know) when developing engine tests. Don will share his part in a small team that developed the GM Engine Oil Life Monitor. He will recall his experiences an expert witness for the Department of Defense. When Don transferred to Worldwide Facilities Group, he spent a significant amount of time in plants and will reveal some unique insights into plant culture. Don developed energy efficiency tests and will relate how he used them to debunk claims of miracle aftermarket additives. He also developed a comprehensive used oil program, and used a beer analogy to get plant buy in. Don returned to R&D and survived deep headcount cuts during GM's bankruptcy. He chaired the GM global engine oil team, and will relate the great diversity of this team and how amusing it was at times. Don will also share his observations on life after GM.

Restrictions: Request one month's advance notice to fit into work schedule

Presentation: Perhaps a Man Can Change the Starts - Engineers Rock! Learn how to lead Non Engineering Colleagues and Succeed!

Biography: Bob Stearns is one of only 98 people in history to lead an organization to win the prestigious Malcolm Baldrige Award. He was the Leader and Architect of Pittsburgh based Medrad's 2003 journey to win the award. The Award is presented by the President of the United States. Bob founded his company, Powerful Potential in 1985. He specializes in:

• Leadership Development
• Strategic Planning
• Customer Loyalty
• Employee Engagement
• Process Improvement

Bob a Professional Public Speaker and has spoken in eight countries. He inspires audience members to optimize their personal potential and their company's potential. Bob is also an author. His highly acclaimed book is titled "Perhaps a Man Can Change the Stars."

Bob worked at Medrad, Inc., a leading developer of medical imaging products where he was the Director of Organizational Development and the Quality and Productivity Center. Bob founded Medrad University, and implemented a number of innovative Organizational Development initiatives including Total Quality Management, Self Directed Work Teams, Career Development, Competency Based Training, and Performance Improvement Teams. He was also responsible for the introduction and implementation of the team based/high performance culture in Medrad's international subsidiaries, and for Medrad's parent company in Germany. Bob worked for the US Department of Commerce as a Senior Examiner for the Baldrige Award. He received the Award for Excellence in Human Resources Development from the American Society for Training and Development.

Bob's company, Powerful Potential, clients include Armco Advanced Metals Corporation, Witco Chemical Company, Respironics, Mine Safety Appliances, International Plastics, Oberg Manufacturing, South Hills Health System, the Pittsburgh Symphony Orchestra, the Carnegie Museum, Harmarville Rehabilitation Center, the Hospital Council of Western Pennsylvania, and Schering AG. Bob has a BS in Psychology from the University of Pittsburgh, and has completed post-graduate classes in leadership development at Carnegie Mellon University. He has taught at several local universities including the University of Pittsburgh and Washington and Jefferson College. He has served as a Director on the Boards of National Church Solutions, the Orchards at Foxcrest, the Pa. Society of Association Executives, the Pa. Association of Non Profit Organizations and for the University of Pittsburgh's Institute of Entrepreneurial Excellence.

Abstract: Engineers make great leaders, but in most organizations they face internal competitors (but not limited to) marketers, Executives and Customers. We all want to develop relationships and to make allies out of our competitors and to make a difference in our personal, and professional lives. However, Roadblocks, Competitive Relationships and lack of Resiliency can get in the way. Your presenter, Bob Stearns will show you how to overcome the Roadblocks and to develop a High Performance Culture. His experience in leading Medrad to win the Baldrige Award, and in working with his clients will help you and your colleagues to thrive! His presentation is informative, humorous and highly interactive.

"Bob was principally responsible for the development of Medrad's employee culture, which drove Medrad to win the Baldrige Award" - Tom Witmer, CEO

Ed Widder, Chicago SAE said: "Bob's program on Innovation was one of the best we've seen!"

The nine strategies Bob will present are from his book, "Perhaps a Man Can Change the Stars"

Improve results, relationships, and dramatically leverage your potential and the potential of colleagues! We needed to find ways for the organization to work together. Bob worked with the Pittsburgh Symphony to plan strategy and to forge new relationships between the Board, Management, the Musicians (union) and Volunteers that allowed us to succeed" - Gideon Toeplitz, Executive VP.

Presentation: Vehicle Assembly Manufacturing—Operations, Management, and Development

Biography: Dr. Tang is an associate professor at Eastern Michigan University (EMU). Before joining EMU, he was a lead engineering specialist at Fiat Chrysler Automobiles (FCA). At FCA for about 16.5 years, Tang had worked on manufacturing system development and launch support for five vehicle programs, and led the specialist team to evaluate, analyze, and help improve the manufacturing system performance and capability of other two new vehicle programs.

Tang’s technical expertise is in the areas of assembly system development, process planning, tooling development management, lean manufacturing, dimensional quality control, welding, launch support, and project management. Tang completed his doctorate study at the University of Michigan in 1999 and earned an MBA degree in industrial management from Baker College. Tang is an active member of SAE, ASME, SME, AWS, and ASQ, has authored two books published by SAE recently and served as associate editor and reviewer for several scholarly journals and conferences.

Abstract: This seminar is intended for engineering students, entry-level manufacturing engineers, and all levels of the non-manufacturing professionals of the automotive industry. The seminar might be viewed as 80% engineering and 20% technical management in nature. The seminar covers the assembly processes, operations management, development of vehicle assembly systems, and/or process planning pertaining to the automotive manufacturing, specific topics include:

Main vehicle assembly processes and operations

Vehicle assembly operations management

Continuous improvement of operational performance

Development of vehicle assembly systems

Process planning for vehicle assembly

Tooling development management for vehicle assembly

Each topic may be presented in about one and a half hours. For an introductory seminar, two or three topics can be combined. The technical content of presentations and time may be adjusted upon request. The presentation file may be shared with audience before seminar. These subjects are also covered in the speaker's two books: "Automotive Vehicle Assembly Processes and Operations Management" and "Manufacturing System and Process Development for Vehicle Assembly" published by SAE.

Presentations:
“Effective Planning: Transition from IC to EV”
Learn how to develop a develop a successful plan to transition from internal combustion to electric vehicles for your Formula SAE team. 

“The Value of Diversity on Your Team”
This lecture is intended for all SAE students who wish to create an inclusive team culture on their teams. 

Biography: Rebecca is a Sales Engineer at B&R as a part of a rotational development program in robotics and automation at within ABB. She has a Bachelors of Science in Mechanical Engineering from the University of Central Florida. As a student, Rebecca was active in Formula SAE for 5 years, serving as business lead, interim treasurer, outreach director, and president. She is passionate about SAE and how it shaped her academic and professional career.

Abstracts:
"Effective Planning: Transition from IC to EV"
This lecture is intended for Formula SAE students who wish to develop a successful plan for transitioning from internal combustion to electric vehicle. This includes a discussion of reorganized team dynamics, project management, and design and material planning.Each presentation is tailored to individual teams and their current operating standards. Rebecca will provide questions for team leaders to organize and discuss EV evolution for their car's systems and learn how to seamlessly transition from IC to EV from a competitive standpoint.

"The Value of Diversity on Your Team"
This lecture is intended for all SAE students who wish to create an inclusive team culture on their teams. This discussion involves an in-depth look at internal bias, external factors that inhibit diversity, what actions can be taken to actively prevent marginalization, and how a diverse team breeds more effective and professional members.

Equipment Needs: Means of presenting PowerPoint via Laptop

Restrictions: None

Presentations & Abstracts:

1. Functional Safety ISO 26262: Why adopt it and why get certified?
   With the increase of vehicle complexity and the addition of new vehicle features and functions, safety related systems are in higher demand in the market. To develop safety systems that are in compliance with ISO26262 is of increasing demand with the burden of proof falling to the OEMs. What does functional safety mean to you as an engineer and to your company. Would not knowing or being compliant to functional safety cost you in the future.

2. Product Development Lifecycle: Why you need to get different engineers in sync.
   Development lifecycles are key to modern product and software development. While it is being used in virtually all companies, not all companies implement it efficiently and tend to segregate the scope of each engineering group to a predefined scope. Find out the value of increasing the exposure of different engineering groups involved in your product development to the bigger picture and what added value does proper utilization of ALM systems can bring you.

3. Model Based Engineering: Best Practices
   Model based engineering (MBE) can cut down the development cost tremendously. However, not all engineers and companies using MBE implements it to its full potential. Whether you are missing styling guidelines, data dictionaries, or any other tools and processes that you can leverage to streamline your software development, it is important to identify the gaps and come up with solutions and explore alternatives.

4. Automotive Functional Safety, Cybersecurity and Safety of the Intended functionality: What are they? How do they align?
   The automotive world has been going through many changes in the last decade. Concern for vehicle safety and security is at its peak with all the new technologies in the vehicle. With reasonable, foreseeable risk assessment and to the best available state of the art technology, the automotive industry embarks on a journey to ensure vehicle safety. With functional safety ISO2626 in its current forefront, the automotive industry is focusing on ensuring the protection of the vehicle on the road from electric, electronic and software failures, particularly one that can go undetected. In order to mitigate these failures, functional safety process establishes a guideline for the automotive industry to ensure the safety of vehicle operation. Another major concern with vehicle connectivity is exposure to hacking. For that cyber security followed closely with SAE J3061 and its upcoming ISO 21434, cybersecurity standards establish a framework for the automotive industry that aims to identify cyber attack vectors and ways to protect against them so that no one can take control of vehicle remotely.  The newest addition to the family is safety of the intended functionality (SOTIF) ISO 21448. SOTIF aims to ensure that the automotive industry develops the right functions and that these functions are protected from misuse. With all these new standards focus on safety and security, automotive engineers are wondering what that means for them and for the future of the industry. With each standard having a unique focus and them complementing each other, a level of understanding is required by the automotive engineers to be able to adapt in a rapidly changing industry. In this lecture you will have a short intro about each standard and how they complement each other.

Biography: Dr. Zaher has worked for 8 years in academia and over a decade in the automotive industry. He received his Ph.D. from the University of Illinois at Chicago in 2013. Dr. Zaher is a functional safety certified automotive engineer with more than a decade of experience in product development using the V-model. Dr. Zaher works with emission related OBD diagnostics for after treatment systems, engine controls, powertrain controls, aftertreatment, HEV and EV systems, driveline systems and configuration management software.

Dr. Zaher led lectures in both USA and Egypt in system dynamics and mechatronics over the course of 8 years. Dr. Zaher’s work revolved mainly around the following areas of the development lifecycle:

1. Systems engineering: working on requirements development, deductive and inductive analyses using DFMEA & FTA leading to system design, functional safety safety mechanisms and ASPICE compliance

2. Model Based Engineering using MATLAB, Simulink and Stateflow to develop mathematical plant models and control algorithms for various systems using rapid prototyping methods to deliver high confidence software, both autocoded and hand coded with compliance to MISRA C and AUTOSAR architecture

3. and Verification and validation of control software and diagnostics for vehicles in MIL, SIL, PIL, HIL, test cells, dynos and vehicles validation.

Restrictions: Request one month's notice to fit into work schedule

Presentation: Reliability of Autonomous Vehicles

Biography: Dr. Jay Zhou is a Fellow of American Society for Quality and CTO at JHZ Strategic QA. Prior to this, he worked for Ford Motor Company for more than 28 years. At Ford, Jay held various positions including Vice President of Ford China Quality and New Model Program Launch, Vice President of Ford Asia Pacific Quality and New Model Program Launch, Ford Corporate Executive Technical Leader and Member of Technology Advisory Board. Jay is Associate Editor for SAE Journal of Materials and Manufacturing and SAE Journal of Passenger Vehicle Systems. He also serves on Advisory Board for Eastern Michigan University School of Engineering QMP. Over years, Jay has trained more than 15,000 people in more than 20 countries. Jay has published more than 30 technical papers, held a US patent on vehicle durability. He has been a keynote speaker and panelist at various international conferences. He was a three-time award winner of Taguchi Robust Design. Jay earned his M.S. and Ph.D. degrees from University of Michigan, Ann Arbor.

Abstract: This lecture provides an introduction to Reliability for Autonomous Vehicle Design and Analysis. It proposes a failure mode avoidance framework for autonomous vehicle reliability development. The lecture will discuss the following topics: • Transport Comparison • Motor Vehicle Fatality by Year • Road Fatality in the World • Drunk Driving Fatality • Auto Recalls • 2021 Autonomous Disengagement • Failure Mode Avoidance • Reliability Models (Redundant Systems) • Robust Design and Robust Engineering • System Engineering

Equipment Needs: Projector with a computer or a cable to HDMI connect to a laptop for presenting a MS PowerPoint presentation, a laser pointer, a wireless clip-on microphone optionally needed if a large auditorium is planned.

Restrictions: No set restrictions. four-week advance notice would be appreciated. Some scheduling flexibility may be necessary depending on other obligations.