Michael Wilson - Engineering Products,
Leading Teams, Delivering Launches!

Oldsmobile Aurora Pneumatic Lumbar Integration

Led the integration and release of a new centralized pneumatic lumbar architecture serving both front seats, coordinating the required seat and vehicle interfaces. The design replaced separate seatback pumps with a single under-driver-seat pump and four-valve module, reducing cost and component count while improving reliability.

• Developed during 1995 for the 1996 model year.
• Approximately 30,000 vehicles annually.
• Eliminated the separate passenger-seat pump and valve assembly.
• Eliminated the passenger-seat harness branch that had supplied the former pump.
• Completed validation and Production Part Approval Process (PPAP) without late redesign.
• Launched on schedule and within budget.

Chevrolet Impala and Monte Carlo Split-Folding Rear-Seat Development

Designed and released new 60/40 split-folding rear-seat systems for two General Motors (GM) vehicles with significantly different package conditions while preserving nearly every structural and mechanical component of consequence.

• Approximately 250,000 vehicles annually combined.
• Preserved Lear's business case for a common structural and mechanical architecture.
• Fold-flat targets achieved despite major package differences.
• Seat-comfort targets achieved for both vehicle platforms.
• Successful launch with no major production issues.
• Basic rear-seat frame design carried forward to later W-body vehicles.

Freightliner M2 Business Class Wiper-System Redesign

Redesigned and released the complete Freightliner M2 Business Class wiper module after Trico assumed the program from the previous supplier. Under compressed timing, developed a Trico production design from the inherited package, including Trico wiper-motor integration, a new unitizing-tube and center-bracket design, Trico-compatible outboard pivot castings, Trico-standard bearings and shafts, new wiper-arm and blade assemblies, and complete kinematic verification.

• Completed the full Trico production design by June 2000 after redesigning the complete system in four weeks.
• Converted the previous supplier design package into a Trico production-ready wiper system.
• Verified vehicle packaging and complete system kinematics.
• Completed the system and component redesign and release, along with the initial prototype build and Design Verification testing, before transferring to the General Motors onsite assignment.
• Production design carried into manufacturing by the succeeding engineer.
• No major design or production issues are known.
• Approximately 35,000 vehicles annually on average.

General Motors W-Body Wiper-System Redesign and Launch Recovery

GMX367 Pontiac Grand Prix | GMX365 Buick LaCrosse

Redesigned and released the complete front wiper and washer systems for the GMX367 Pontiac Grand Prix and GMX365 Buick LaCrosse after Trico assumed the programs from the previous supplier following the Alpha prototype phase. When the first Trico Beta systems showed severe high-speed dynamic wipe-pattern growth, developed a third-hard-mount countermeasure and recovered the design in time for Gamma prototypes and an on-schedule launch.

• Complete Trico front wiper and washer systems redesigned and released.
• High-speed cowl and A-pillar contact eliminated through a third-hard-mount countermeasure.
• Corrected hardware delivered in time for the Gamma build.
• Validation passed without another major redesign.
• Production launched on schedule.
• More than 200,000 vehicles annually.

General Motors Theta Vehicle-Family Wiper and Washer System Development

GMT191 Chevrolet Equinox | GMT192 Pontiac Torrent | GMT193 Suzuki XL7

Directed the quotation, concept development, architecture definition, and customer technical work for the GMT191 Chevrolet Equinox, GMT192 Pontiac Torrent, and GMT193 Suzuki XL7. After award, an engineer working under my supervision handled much of the day-to-day engineering workload while I retained accountable technical responsibility, major technical decision-making, customer interface, and issue-resolution leadership through all three on-schedule launches. The front wiper module, arms, and blades were fully common across all three applications.

• Front wiper module, arms, and blades fully common across all three vehicles.
• Shared Equinox/Torrent rear module recovered from a critical water-ingress issue discovered during Design Verification testing.
• Corrective design changes carried into the later XL7 application.
• Accountable technical responsibility retained through three on-schedule launches and launch support.
• Combined planned annual production approached 245,000 vehicles.

Pedestrian-Protection Wiper-Pivot Innovation

Patented breakaway ferrule · Production frangible casting

Anticipated emerging European pedestrian-impact requirements by originating and independently validating a patented breakaway wiper-mounting concept, then led development of a simpler frangible cast-pivot architecture. The production design preserved full wiper-system durability and stall-load capability, reduced casting material by approximately 15%, and became Trico's standard pivot architecture.

• Patented breakaway concept passed internal loading and independent impact validation.
• Finite element analysis accurately predicted the production pivot's fracture location and load.
• Production architecture passed vibration, durability, stall, snow-block, and low-temperature testing.
• Approximately 15% casting-material reduction with moderate cost savings.
• Successfully transferred from validated concept into production applications on the Hummer H2 and Dodge Ram DS.

Dodge Ram Fastener-Free Wiper Mount

Served as the responsible engineer for the complete wiper-system quotation and program award, then continued as Engineering Manager and technical adviser during production development. In response to a Chrysler manufacturing request, developed a fastener-free passenger-side pivot attachment using a Z-shaped tang, rubber isolation grommet, and rotational installation sequence.

• Eliminated one fastener and one difficult vehicle-assembly operation.
• Enabled one operator to install and secure the module from the driver side.
• Preserved the system's isolation and tolerance-management strategy.
• Passed full durability, reliability, vibration, stall, snow-block, impact, and temperature validation.
• Launched without modification after final production release.
• Later applied to Ram 2500 and 3500 models.
• No known post-launch issues associated with the attachment.

Maserati M156 Complete Wiper-System Development

Won and led Trico's first Fiat production program, serving as Engineering Manager, lead development engineer, technical quotation owner, and principal engineering interface with Fiat in Torino. Directed complete LHD and RHD wiper-system development through design freeze, validation, industrialization, and launch.

• Delivered complete LHD and RHD systems built around a common application motor.
• Implemented Trico's first 90-degree integrated motor-cover connector orientation.
• Led Trico's first full-vehicle three-dimensional wiper CFD study.
• Met a 220 km/h aerodynamic-performance requirement.
• Applied the established frangible pedestrian-protection pivot architecture.
• Passed Fiat's formal design-freeze gate in Torino.
• Launched on time in 2013 with no meaningful post-launch issues.
• Helped establish the credibility that led to the later Fiat Ducato award.

Scania NCG Complete Wiper-System Development

Won and led Trico's first European heavy-duty commercial-truck wiper-system program, integrating a new 24 V, 50+ Nm motor with separate LHD and RHD modules, 28-inch blades, blade-mounted washer nozzles, stringent NVH requirements, and Scania-specific validation.

• Selected by Scania as development supplier May 2012; production award November 2013; first G-series SOP in June 2016.
• Original center-grommet concept helped control module roll and pattern growth.
• Maintained less than 50 mm cowl pattern growth from nominal park.
• Completed 4.5-million-cycle durability plus Scania Combined Tests.
• Validated 100% mud-test cleaning of the wiped area within two cycles.
• Passed formal Scania design freeze / technical approval in Södertälje.
• Launched on time with very few post-launch issues.