SUMMARY

• Experience managing staff: up to 10 engineers and designers
• Completed over 12 continuous improvement projects in the Automotive Industry.
• Excellent Technical Writing, Public Speaking, and Presentation skills
• Lectured classes and certified up to 70 greenbelts.
• Experience in tracking projects, budgets, and meeting on time delivery
• Experience leading cross functional teams in fast - cycle new product development
• Able to quickly respond to random issues and provide viable solutions
• Experience in EMC/EMI testing for electronics.
• Experience in Hydraulics Circuit Design and P&ID diagrams.
• Finite Element Analysis: Linear and NonLinear Stress, CFD, Heat Transfer, Fatigue
• Expertise in GD&T and ASME 14.9 (Dimensioning and Tolerancing).
• Automotive Standards: ASTM, SAE, OEM, FMVSS (49 CFR 571), NHTSA
• Quality management systems, ISO-9001, AS9100, ISO-9000/2000, QS-9000, TS-16949
• Functional Safety of Electrical HW, ISO26262, IEC 61508, IEC 61511, FMDEA, FMEA, FTA.
• Design Verification and Production Validation (DVPV)
• Experience (APQP) - PPAP, DFMEA, DVP&R (test summary), SPC, DFM,MSA, PFMEA, PSW
• Experience using Covisint, GQTS, PRR, PRTS
• Experience with ECR/ECN, EBOM
• Experience writing and receiving RFQ/RFP, submitting Proposals/Tenders, and Purchas Orders.
• Design & Release experience using GPDS or eFPDS processes at Confidential Motor Company
• CAD: CATIA V5, Solidworks, PRO E & CREO, NX-Unigraphics, AutoCad, Microstation.
• Knowledge in Thermal-Fluids, Solid Mechanics, Machine Design, Electrical Design, and Software Programming, Electronics, Microprocessors, embedded, Digital Design

TECHNICAL SKILLS

3D/2D Software: Digital Buck, Catia V5, PRO E Wildfire 2.0, CREO, Solid Works, Auto Desk Inventor, AutoCAD, NX Unigraphics, Mircorstation

FEA Software: Ansys, AbaqusMS Word, PowerPoint, Outlook

Programming Languages: C/C++/C#, Java, VB.NET, Assembly LanguageHAZLOC Knowledge of ATEX, NEC, IEC, UL, CSA, NFPA-79, and hazardous areas such as Zones (0,1,2) and Class ( I, II).

PROFESSIONAL EXPERIENCE

Confidential, Houston, TX

Lead Mechanical Engineer

Responsibilities:

• Supervising: Supervised Junior Engineers, Designers, and Drafters to meet project time lines by prioritizing and allocating task.
• Project Design Lead: Team Lead on a $20M project for BP America, Shah Deniz 2 in Azerbaijan, and supervised the design in accordance to ANSI/API 6A/API 17D, API 17F, ASME Sec IX, ASME Sec VIII-DIV2 standards, and customer requirements/SOR.
• Project Management: Monitor project performance against an agreed plan and budget and initiates corrective action where appropriate to ensure projects are completed on time as well as revenue forecasting over the project duration.
• Design Qualification Testing: Participate in lab testing (hydrostatic body test, drift test, etc) per API 6A, PSL3, and analyze test data to determine if design meets client or other internal specifications.
• DFMEA: completed P diagrams, Past Problem History List or lessons learned and cascaded to DFMEA to capture, failure modes, special characteristics and ranked according to RPN (severity, occurrence, and detection).
• Product Standards: Created and validated new product design standards, and worked with project team on a daily basis to drive standards and guidelines for the design. Wrote site receipt test procedures, functional test procedures, and maintenance and storage procedures for the Subsea equipment. Tailored procedures to the scope of supply for various customers’ projects.
• Technical Documents: created Design Files, FEA Reports, Engineering Test Reports, Test Procedures, and Engineering Specifications.
• Procedures: Review manufacturing procedures, engineering procedures and materials specifications, processes and documentation in order to determine that applicable industry design requirements are satisfied.
• Shipping and Handling Procedures: wrote shipping and handling requirements for subsea products to be shipped internationally and domestic per customer and purchase order request.
• Welding: Inspected Electron Beam Weldments (EBW) and Coupon Testing on weldments and rejected or accepted per welding guidelines and ASME IX.
• Customer Interface: Participated in client meetings to ensure customer care and feedback is at the highest priority.
• BOM /ECN /ECR: Generated Bills of Materials and initiated Engineering Change Requests (ECR's) and Engineering Change Notices (ECN's) to compensate or correct design errors for parts that have already been released.
• Non Conformance Reports (NCR): Evaluating and determining the disposition of non-conforming parts for repair, scrap, or leave-as-is.
• Flange Design: sized and designed API 6A and ASME Flanges for different applications.
• Drawings and 3D Models:used Pro E CREO to create 3D Models, and drawings for Subsea Products.
• Finite Element Analysis: used ANSYS Workbench to perform FEA analysis on numerous Pressure Vessels and Flanges to evaluate Non-Linear and Linear Von Mises Stresses per design allowable set by API 6A/17D/ASME VIII-DIV2.
• Plastic Injection Molding: plastic poly acetylene resin was selected to make numerous protective covers for shipment. Design numerous molds using PRO E/CREO.
• Rapid Prototyping: produced many parts using the rapid prototyping process of stereolithography.
• CNC Machines: wrote G Code for CNC machines. Taught classes and trained employees in G Code programming.

Confidential, Houston, TX

Engineer

Responsibilities:

• Supervised Operations: Supervised field operations and performed reliability studies.
• Risk and Uncertainty Management Standards: Participated in RUMS (Risk and Uncertainty Management Standard), (Hazard Identification Study), HAZOPS.
• Functional Safety(IEC 61511, IEC61508): supported Subsea Team to develop safety plans to ensure compliance, and cascade safety requirements to the systems, subsystems, and component levels for BOP, and LMRP hardware for Electro Hydraulic Hardware used offshore. Work details included:
• Assisting product development teams in defining and managing hardware technical safety requirements for subsea electronic components.
• Conducting functional safety analysis
• Planning, performing, and reporting on functional safety verification and test activities
• Analyzed fault tree analysis safety reports.
• Defined Functional Safety Requirement for Electro Hydraulic Equipment.
• Performed risk analysis of a potential hazard by looking at the Severity, Exposure and controllability of the vehicle operating scenario.
• Implemented FMEDA to determine fault behavior and failure rates resulting in safe failure fractions (SFF).

Confidential, Houston, TX

Senior Engineer

Responsibilities:

• Engineering Team Lead: Subject Matter expert and Team Lead on numerous projects totaling $15 mil. Designed Subsea equipment per SOR or customer requirements.
• Project Management and Planning: Manage planning and execution schedule for Wellhead equipment including design, manufacture, and installation phases. Used Primavera P6 to monitor and analyze performance data.
• Stage Gate Management: implemented many new product designs utilizing the 5 stages such as Preliminary Investigation (reviewing SOR from customer, projecting timelines), Detailed Investigation (putting together 2D concept layouts), Development (designing 3D models and assemblies, calculations, FEA), Validation (qualification testing of new design per test procedures, and API 6A), and Launch (releasing the drawings).
• Risk Assessments:used DFMEA to develop root cause failurematrix to evaluate the risk and provide recommendations for improvements.
• Trouble Shooting:Define, coordinate,and provide technical knowledge in interpreting testingresultsfrom FATand providing viable solutionsor improvementsto optimize design.
• Design Qualification Testing: Participate in lab testing (hydrostatic body test, drift test, etc) per API 6A, PSL3, and analyze test data to determine if design meets client or other internal specifications and wrote engineering reports.
• Writing Technical Documents or Reports: writing Design Files, FEA Reports, Engineering Reports, Test Procedures, and Engineering Specifications.
• BOM and ECN/ECR: Generated Bills of Materials and evaluated Engineering Change Notices (ECN's) and Engineering Change Requests (ECR's) as directed.
• Managing employees: Managed designers, drafters to complete 3D models, layouts, drawings, and trained and supervised many new hire engineers.
• Finite Element Analysis: used ANSYS WorkBench and ABAQUS 6.12 to perform FEA analysis on numerous Subsea Products. Analysis involved linear static and non linear.
• Material Selection Perform materials selection analysis per API 6A and NACE.
• 3D Modeling and Drawings:used Autodesk Inventor and Solidworks to 3D Models and drawings forForgings or Preheat Treatment,Rough Machine, Assembly, Finish Machine, Weld Overlay or Clad, Detail Drawings with GD&T, Fabrication, and Schematic Drawings (P&ID).
• Firmware and Software Design: wrote embedded code in C++ to control an analog to digital (A/D) board which was connected to thermocouples, optical pyrometers, calorimeters, and strain gages which were used in high temperature material tests. Also, designed, reviewed, coded, tested and debugged numerous real-time embedded software using C/C++.
• Labview Software: redesigned, modified, and developed new LabVIEW software for hydrostatic pressure testing, and data acquisition.

Confidential, Houston, TX

Mechanical Engineer

Responsibilities:

• New Product Design: Demonstrated ability to manage new products and working to meet timing for prototype and production release. Design numerous parts according to customer requirements and engineering standards and specifications.
• Project Management and Planning: Manage planning and execution schedule for subsea equipment including design, manufacture, and installation phases.
• Primavera: was used for scheduling and metrics creation.
• Stage Gate Management: implemented conceptual operation road map for moving new products from idea to launch by utilizing the 5 stages such as preliminary investigation, detailed investigation, development, validation, and launch.
• Project Scheduling: scheduling and forecasting dates for project milestones per stage gate management process or cycle.
• Scope of Supply: reviewed project scope of work for products and services and ensured the timely delivery of the agreed technical scope of supply as defined.
• Risk Assessments: support teams and provided risk assessment, and contingency planning and mitigation.
• Tendering: provided support to tendering group for clarification/evaluation, contractor/vendor selection and contract/purchase order negotiation and placement.
• Writing Proposals: Proposals are written with background information of product and financial savings.
• BOM and ECN/ECR: Generated Bills of Materials and Engineering Change Notice OR Engineering Cost Request.
• PO & RFQ: submitted numerous RFQ to suppliers for work to be rendered, and ordered parts and services per PO issued.
• Non Conformance Reports, NCR: Disposition non-conforming parts for repair and establish testing requirements.
• Product Testing or FAT: managed factory acceptance test for new products and customer orders.
• Hydraulic Schematics or P&ID: developed numerous hydraulic circuits or P&ID to operate subsea equipment.
• GD&T: interpreting and correcting detail drawings with Geometric Dimensioning and Tolerance.
• Finite Element Analysis: used ANSYS, COSMOS, and ABAQUS, to generate results for linear and nonlinear static stress analysis, thermal analysis, fatigue analysis, and NVH analysis

Confidential, Houston, TX

Project Engineer

Responsibilities:

• Product Design of Downhole Tools: Demonstrated ability to manage and deliver products to meet timing for prototype and production release for downhole tools.
• Stage Gate Management: implemented conceptual operation road map for moving new products from idea to launch by utilizing the 5 stages such as preliminary investigation, detailed investigation, development, validation, and launch.
• Product Development: management design engineers, and design parts according to specifications for sheet metal design, plastic injection molding, and electronics packaging.
• Embedded: Design and develop program module to send data to paging transmitter via RS232 port using C++.
• Software Application: created customize engineering applications using Visual Basic and JAVA.
• Labview Software: developed new LabVIEW software to work with Solidworks and create realtime simulations.

Confidential, Detroit, MI

Project Engineer

Responsibilities:

• Designed & Release: Designed and released parts by supporting WERS releases and drawing updates from P-release through launch while meeting FMVSS requirements.
• Safety Standards: Enforce/improve standards of safety and ergonomics, quality, productivity, and housekeeping with respect to 5S standards
• Managed Projects and Suppliers: Demonstrated ability to manage and deliver products and worked with suppliers to meet timing for prototype and production build.
• Packaging Studies: using Digital Buck and Catia V5 to perform packaging studies for parts by checking clearances to matting components per System Design Specification (SDS) and Federal Motor Vehicle Safety Standards (FMVSS).
• Functional Safety: Supported team to develop safety plans to ensure compliance, and cascade safety requirements to the systems, subsystems, and component levels. Work details included: (1.) Assisting product development teams in defining and managing hardware technical safety requirements for electronic components (2.) Compiling together item definition of V model of all activities of system boundary (3.) Conducting functional safety analysis as required and implementing risk reducing measures per Automotive Safety Integrity Levels (ASIL) levels A (lowest), B, C, D(highest), and QM(no risk measures) (4.) Planning, performing, and reporting on functional safety verification and test activities (5.) Analyzed fault tree analysis safety reports. (6.) Defined Functional Safety Requirement for Confidential internal safety in restraints (7.) Implemented FMEDA/FMEA/FTA to determine fault behavior, Single Point Failure (SPF) and Latent Failure (LF) (8.) Implemented ASIL determination tables using three factors Severity (S0 to S3) x Exposure (E0 to E3) x Controllability(C0 to C3) of vehicle operating scenarios (9.) Performed Hazard and Risk Analysis (HARA) to look for ways of improving the safety Architecture by implementing a Safety Mechanism (10.) Performed Hardware ASIL Decompositioning ( System failure logic AND vs OR, ASIL Algebra) in order to lower the required ASIL of a system caused by redundancy. (11.) Compile together Summary of Safety Requirements per ASIL for Design, Development, and DVPV.
• Problem Solving Methods: utilized many methodologies when problems occurred such as 8D or Global 8D,and DFSS or DMAIC.
• Enterprise Resource Management (ERM) Software: (1) WERS: to release parts, BOM’s, ECN or ECR’s (2) GPIRS: to order parts and Bill of Materials (3) Analytical Warranty System: to pull warranty claims to investigate parts with high rate of failure (4) AIMS, Automatic Issues Management System (5) eFDVS-manage programs through product development process to Engineering Signoff or completion.
• Design Verification and Production Validation (DVPV): worked with suppliers to implement DVPV to ensure that when a product is released, it performs as expected through design verification and validation testing.
• FMVSS Requirements: implemented to ensure parts meet government regulations and requirements. Also, executed FMVSS 207/210 seating systems/seat belt assembly anchorages to ensure effective occupant restraint and to reduce the likelihood of failure.
• APQP: worked with suppliers and approved check list for APQP (Advance Product Quality Planning), PPAP (Production Part Approval Process) to ensure released parts meet quality targets, RRCL, DVP&R, P-diagrams, MSA, SPC, Gage R&R, DFMEA, PMEA,.
• GPDS (Global Product Development System)/FPDS: used metrics and milestones to design, test, and release part into production while meeting on time delivery.
• Managing Cost: Manage cost effectively through cross-functional activities with Suppliers and Purchasing
• Black Belt Projects: Managed a variety of projects focused on solving critical business issues for the Brakes Department across all vehicle platforms. Managed and completed a total of 6 warranty projects with savings up to 3 million.
• Warranty Cost Reduction: utilize the 6 sigma tools and methodology to reduce warranty costs by analyzing repairs and cost per vehicle and providing recommended actions to make improvements.
• Design of Experiments (DOE) & DFSS: Used statistical methods to collect data and develop transfer functions for a response based on given inputs (x1, x2, x3,). Using regression techniques to optimize a systems output response while utilizing scorecards.
• Gage R&R: was used to establish a capable measuring system by measuring the variation of repeatability due to equipment and reproducibility due to operator or appraiser.
• Teaching DMAIC or 6 Sigma Process: Taught classes and certified numerous greenbelts and served as mentor.
• P-diagrams: was used as a tool to accommodate FMEA’s to identify intended inputs and output responses for the subject under investigation.
• Technical Presentations: provided technical presentations to management by conveying issues and potential solutions while utilizing the DMAIC tools in Six Sigma such as DOE, Control Charts, Fishbone Diagrams, Cpk analysis, Confidence Intervals, and Hypothesis testing.
• Process Improvements: optimizing system processes by evaluating metrics(CTQ, CTC, CTD) and analyzing process input to output such as Final Yield(FY), Through Put Yield(TPY), Rolled Through Put Yield(RTY), Normalize Yield(NY), Defects Per Unit(DPU), Defects Per Million Opportunities(DPMO),
• Quality: Solid understanding of AS9100, ISO-9000/2000, QS-9000 and/or TS-16949
• Lean Six Sigma: Utilize Lean Six Sigma-emphasis on Kaizen Continuous Improvement and Kanban-Just in time method of parts procurement.
• Kanban: implemented Kanban inventory systems resulting in streamlined inventories and increased inventory by reducing lead times.
• 5S Implementation (Sort, Set in Place or Order, Shine, Standardize, Sustain): was implemented by sorting or selecting a work order to maximized efficiency, planned a cleanliness campaign, standardize methods, and sustained the process.
• Value Stream Mapping (VSM): used VSM to map process flow and analyze waste and improve efficiency.
• Continuous improvement: used methodologies in Six Sigma and lean to make ongoing improvements, and cultivated and championed a continuous improvement team environment throughout the entire hourly workforce at the Confidential Focus Assembly Plant.