Rabie Khalil

**** ***** ***** **., **********, IL 60586, USA

abholy@r.postjobfree.com +1-815-***-**** +1-630-***-****

Engineering Management Profile

Concept to Prototype Design & Engineering Research & Development QA

& Leadership

Results-oriented and talented engineering leader with extensive experience

designing and delivering groundbreaking improvements to systems and

technology of new and existing products; adept at identifying opportunities

for enhancements to performance, reliability, differentiation, innovation,

and cost. Proven track record of collaboration across global operations and

business units to lead the end-to-end engineering lifecycle spanning

design, development, testing, and launch; consistently achieve and exceed

regulatory and ISO compliance objectives. Background of success in multiple

sectors and industries; Six Sigma expertise, with proven leadership,

problem-solving, decision-making, and communication skills. Technical

proficiencies include...

Products Hybrid Hydraulics, Energy Recovery, Electro-Hydraulic (EH) /

Hydrostatic Components/Systems, Construction Equipment, Highway and

Off highway Machines, Combustion Engines

Industrie Fluid Power, Aerospace, Oil & Gas, Construction, Marine, Agriculture,

s Industrial, Military

Tools PRO-E, FEA, CFD, Dynasty, DATK, FMEA, MATLAB, Auto-Cad, MS Visio, MS

Excel, MS PowerPoint, MS Word, Project Management, APQP (Advanced

Product Quality Planning)

Technolog Intelligent: Hybrid Machines, Energy Recovery,

y Brake-Steering-Implement-Fan Drive Systems By Wire, Autonomous

Machines, Fuel-Cell Powered Machines, Enterprise Innovative-Integral

Solutions-Commercial Viable-Fuel Efficient-Cost Effective Hydraulic

Systems, Mobile/Immobile Machines

Professional Experience

Global Chief Design Engineer (Contract)- SANY H.Machinery Ltd., Kunshan,

Jiangsu, China 2013 to 2014

Directed workflow of 90+ Engineers spanning multiple teams (New Product

Introduction (NPI), Strategy, Stakeholder Review, Validation, and Survey).

Led creation of long-range (eight-year/four-generation) excavator product

development strategy encompassing multigenerational product/process plans

(MGPP) and vision across seven machine models/sizes. Drove continual

improvement through process management methodology, Six Sigma, DMEDI, and

DMAIC initiatives. Managed design, development, and improvement of

products. Implemented cost control and process control measures related to

technical R&D and production. Ensured alignment of all designs with company

expectations, performance benchmarks, and industry standards. Recruited,

motivated, and mentored R&D Engineers. Selected projects include...

< SY2000x MINING NPI & TECHNOLOGIES: Entrusted with driving multiple

engineering initiatives aimed at securing market leadership and global

competitive edge for hydraulic excavator products. Optimized excavator

product designs (layout, powertrain matching, and hydraulic systems).

Created product introduction roadmap strategy.

. Defined long-range business measures, including 4-5% global market

share and 10% domestic market share by 2020.

. Created performance benchmarks compared to SC model to propel

continuous improvement, including but not limited to 10+%

reduction in machine cycle times, 7% reduction in fuel

consumption, 2% increase in overall engine efficiency with a 5%

reduction in engine noise, and a 5-10% improvement in hydraulic

efficiency while achieving 10% reduction in hydraulic system

pressure.

Chief Engineer, Hydraulic Excavator (Contract) - Zoomlion Co. Ltd.,

Changsha, Hunan, China 2011 to 2012

Held accountability for defining 12-year/six-generation product strategy

for hydraulic excavator product line with MGPP and vision. Supervised and

managed new technology introduction (NTI), NPI, strategy, stakeholder

review, validation, and survey teams totaling 60+ engineers. Identified

opportunities for process enhancement through Six Sigma, DMEDI, DMAIC, and

process management methodology deployment. Built and led project teams;

oversaw business requirements analysis, project schedules, budgets, and

deliverables. Selected projects include...

< ZE360x/ZE230x/ZE60x NPI & NTI : Directed Hydraulic Excavator Catalyst

Program (HCP) and related development processes to drive market

dominance. Created NTI/NPI roadmap strategy and stakeholder

management/communication plan.

. Defined first generation HCP goals and related strategy for

building domestic market share by 10% increments in 2014, 2015,

and 2017 as well as establishing 30% global market share by 2017.

. Established ambitious engineering objectives including zero

machine structural failure by 2014; 80% reduction in component

failure and component warrantee costs; 10% increase in hydraulic

component fill rate and sub-hydraulic circuit response; and 20%

reduction in engine fuel efficiency, coupled with 3% increase in

engine efficiency and 7% reduction in engine noise.

Senior Technology Team Leader (Contract) - Parker Hannifin Corp., Romeo,

Michigan, USA 2010 to 2011

Brought on board to oversee development of hydraulic drivetrain system

solutions through in-depth analysis of subsystem/component requirements and

specifications. Incorporated established product utilization, cost

optimization, manufacturing, and life cycle workflows into new designs.

Developed predictive models to verify system performance and orchestrated

validation process; composed system documentation, including training

materials and maintenance recommendations. Drove refinement/enhancement of

designs and products. Participated on high-level projects and knowledge-

sharing initiatives. Selected projects include...

< UTILITIES HIGHWAY HYDRAULIC HYBRID DRIVE TRUCKS: Perform

diverse/complex design of systems and components by applying

established engineering principles and developing new analysis tools.

. Reduced per-machine costs by 33%+-including 80% reduction in parts

and plumbing-through 2 original designs for friction brake

isolation control valve and finite element analysis (FEA).

. Improved overall hydraulic hybrid system, reducing plumbing costs

by 135%+ per machine and delivered optimal filtration circuit

design.

Chief Hybrid Technology Officer (Contract) - Hydrahybrid, Inc., Joliet,

Illinois, USA 2009 to 2010

Launched and managed hybrid technology consultancy servicing key

engineering clients. Elicited technical and functional requirements and

developed innovative and original designs utilizing expansive product

development experience. Administered company financials. Selected projects

include...

< HIGHWAY & OFF-HIGHWAY MACHINES ENERGY RECOVERY ADVANCED TECHNOLOGY:

Spearheaded design of common hydraulic hybrid technologies in line with

ambitious energy recovery objectives.

. Achieved 40%+ reduction in per-machine fuel consumption by

producing 2 original designs for braking energy recovery hydraulic

hybrid components/system.

. Innovated original steering energy recovery hydraulic hybrid

components/system that realized 12%+ reduction in fuel consumption

per machine.

. Additional design work includes 2 Hydraulic hybrid transmission

drive system/components and 2 hydraulic hybrid storage energy road

maps that required less space, and weight.

< ADVANCED COMBUSTION ENGINE TECHNOLOGY: Designed common variable

displacement combustion engine featuring displacement, energy, fuel

consumption and power on demand. Assessed the diesel, gas, and gasoline

engines to benefit from revolutionary design.

. Produced 1 original variable displacement combustion engine design

that achieved ambitious goals related to fuel consumption,

combustion efficiency, and engine efficiency.

Senior Engineer, Design - Caterpillar, Inc., Joliet & Mossville, Illinois,

USA 2001 to 2009

Held full responsibility for leading design of systems, components, and

control strategies for new and existing construction equipment and

technology within Advanced Systems Division and Technology & Solutions

Division; led new product introductions (NPI) and continuous product

improvement (CPI), developing innovative solutions to field issues

demonstrating a significant impact on warranty costs. Managed multiple

concurrent projects across all R&D phases, including design, field-testing,

and production. Collaborated with Intellectual Property teams to ensure

design originality. Provided representation presentation at industry design

events. Served as strategic consultant for short- and long-range systems'

innovation and launch planning. Managed teams of 2-4 engineers and

technicians and oversaw up to $3M. Selected projects include...

< D11, D10, D9, D8, D7, and D6 Tractors: Redesigned common hydraulic

cylinders' piston valves, leveraging the failure mode and effects

analysis (FMEA) process to identify optimum design.

. Produced 4 original designs and evaluated computational fluid

dynamics (CFD) and finite element analysis (FEA) to recommend

specific design for development.

. Benefits of new design included elimination of $20M+ in ongoing

warranty costs, zero break failures, and an overall reduction in

parts.

< 312x Hybrid & Fuel Efficient Hydraulic Excavator Prototypes: Hand-

selected to evaluate commercially viable, advanced common hybrid

hydraulic systems featuring fuel efficiency, cost effectiveness, and

energy recovery with a goal of achieving a 50%+ energy savings.

Designed 3 groundbreaking hydraulic systems' concepts spanning

schematics, structure, functional specifications, components, and

circuits, demonstrating a potential for significantly more than 50%

reduction in power / fuel demand / engine size / pump size / components

weight and space.

. Created bidirectional hydraulic transformer capable of converting

energy losses into mechanical power instead of heat, introduced

the first load change independent hydraulic system characteristic.

. Developed original power plant design featuring storage and

provision of hydraulic energy from the transformer, eliminating

conventional hydraulic tanks and accumulators.

. Created and delivered 15 concepts that identified potential fuel

savings of 18-39% circuit dependent.

. Evaluated existing product lines and built a roadmap for potential

applications.

< 793x, 773x, 777x Autonomous Off-Highway Truck Braking Pilot &

Prototypes: Pioneered design of innovative brake-by-wire braking

systems for service, parking, and secondary braking providing features

of anti-lock braking system (ABS), traction control system (TCS), and

auto-retarder control (ARC) systems, improved braking response times,

and substantial reduction in development costs.

. Conceptualized 13 prototypes EH braking systems; created 8 pilot

concepts for selected prototype, including hydraulic schematics

and bill of materials, consistently communicating with supplier.

. Selected design featured distributed system configuration allowing

improved response and performance, as well as supporting ABS, TCS,

and ARC features while also reducing traditional plumbing

complexity and cost. New system improvements included 60%

reduction in accumulator volume, 55% reduction in total

accumulator weight, 87% reduction in accumulator low idle recovery

time, 63% reduction in accumulator low-idle charge time, 12%

reduction in accumulator cost, 40% reduction in the charging valve

cost per machine, and achievement of ISO 3450 standards.

. Signature tests of new EH braking systems demonstrated a three-

fold decrease in response times over the Atlas 777F and a 3000%+

reduction in natural bleed down; retrofitted existing products.

< 793x, 773x, 777x Autonomous Off-Highway Truck Steering Pilot &

Prototypes: Introduced original solutions for primary, redundant, and

secondary steer-by-wire hydraulic steering systems.

. Designed 3 EH steering systems, with the final, selected design

offering substantial improvements to performance, system response,

and cost benchmarks.

. Benefits included $22+ savings per unit, 74% reduction in torque,

heat load reduction, and ISO 5010 alignment.

< 980NTI Medium Wheel Loader Steer-by-wire, implement, Fan Drive, and

Brake Charging System Prototypes: Created, tested, and recommended 37

designs for integrated, primary-redundant-secondary EH steering, lift,

tilt, and auxiliary EH system, fan drive, and brake accumulator

charging systems. Introduced innovative integral EH steering and

implement designs and solutions, featuring:

. "On-demand" integral steering control valve which reduced fuel

consumption by 7.3% at low load.

. Secondary steering pump drive which reduced heat load by 1.8

kw/min at 40 km/hr and 0.8 kw/min at 16 km/hr and reduced cooling

package and fuel consumption for an annual cost reduction of

$400K.

. Integral lift-ride control valve which saved 7.6% on fuel, reduced

the accumulator max filling pressure, improved the machine ride

performance, and reduced costs.

. Fan drive and brake accumulator charging system redesign resulting

in a $1.3M annual savings.

< Additional Projects: Steer-by-wire steering system for 420E Backhoe

wheel Loader prototype, fuel cell power utilization for R1300 Mining

Wheel Loader prototype, compact / low-cost auto-leveling control system

for Motor Grader, track adjustment management system (TAMS) for 345C

Hydraulic Excavator, track-hunting idler for D11R Tractor, EH

independent metering valve (IMV) for Wandfluh EVDR2500 and others (23

total).

Product Designer - Teleflex Canada, Ltd., Richmond, British Columbia,

Canada 1999 to 2000

Designed systems for boats, performing design, engineering, assembly,

testing, installation, and commissioning. Directed draftsperson and bill of

material preparation. Selected projects include...

< Power Steering Control Valve & Helm: Designed for single and twin,

outboard and inboard boat motor.

< Hydraulic System: Created tilting and trimming hydraulic system and

mechanism for outboard motor.

Mechanical Engineer - Finning Canada, Vancouver, British Columbia, Canada

1997 to 1999

Created prototypes for aircraft refueling tractors and trucks, designing

engines and systems / controls, including hydraulic, electrical, air;

collaborated with manufacturers such as Caterpillar, Bosch-Rexroth, Parker,

and Hydra-Force to meet functional and technical specifications. Supervised

drafting and shop staff across entire lifecycle of design, development,

testing, and commissioning, holding responsibility for quality assurance

(QA). Wrote service, parts, and maintenance manuals and provided field

service and repair support. Selected projects include...

< FC100A, FC100B, FC100C, FC150A, FC150B, FC75A Prototypes: Designed all

systems and controls for truck and tractor prototypes.

** Additional engineering experience with diverse North America and

overseas companies; details on request **

Education & Credentials

Bachelor of Science in Mechanical Engineering Zagazig University,

Zagazig, Egypt

Licensure & Certification: Egypt Engineers Syndicate (License # 25/6990),

Cairo, Egypt

Construction Machinery Certificates (Japan International Cooperation Agency

- JICA): Komatsu, Shin Caterpillar Mitsubishi, Kobe Steel, Hitachi, Sakai,

TCM, Marumma, Hino, & Nissan (For hydraulic control, components, & systems;

engine; undercarriage)

Professional Development: Six Sigma Green Belt Certified Project

Management Advanced Product Quality Planning Caterpillar Special

Characteristics Failure Mode & Effects Analysis (FMEA) Pro-Engineer I &

II Basic, Advanced Hydraulic & Control (Dynasty) I Dynamic Systems:

Analog & Digital Control Strategies Advanced Mechanical Vibrations

Optimizations of Mechanical Systems AutoCAD 12

Associations: The Association of Professional Engineers & Geoscientists of

the Province of BC, Canada

Arab American Association of Engineers & Architects (AAAEA), Chicago,

Illinois, USA

Patent History

US Patents: Electro-hydraulic steering control system (7,200,993) Electro-

hydraulic system for fan driving and brake charging (7,240,486) On-demand

electro-hydraulic steering system (7,434,653) Crowd-force control in

electrically propelled work machine (7,519,462) Bidirectional hydraulic

transformer (7,775,040) On-demand electro-hydraulic steering system

(7,849,956) Integrated load-sensing hydraulic system (11,392,771) Dual

force hydraulic steering system (11,410,167) Electro-hydraulic braking &

steering system (11,261,541) Hydraulic cylinder having piston-mounted

bypass valve (8,444,400)

** Extensive listing of patents filed available upon request. **

Contact this candidate