Ali Kousari, P.E.

St. Louis, MO

Experience Summary:

Registered professional engineer with three Masters Degrees in Business Administration, Mechanical Engineering and Computer Science. Background includes successes in aviation technology, manufacturing, consulting engineering, power generation, control system design, wiring design, and software engineering. Extensive experience in certification, stress analysis, design, installation, and trouble shooting of engineering systems and software packages. ASME Senior Level Certified in GD&T. Six Sigma Green Belt certification.

Professional Experience:

Stress, Design and Certification Engineer Sept.2008 - Present

Various Short and Long Term Contract Positions at: Dassault Aircraft Services STC ODA, Zodiac Aerospace, Santa Maria, CA; Air Methods, Englewood, CO; Jet Aviation, Cahokia, IL; Bizjet International, Tulsa, OK; Hawker Beechcraft, Little Rock, AR; Jamco America, Everett, WA; Applied Engineering Ltd, Wilmington, OH; Midcoast Aviation, Cahokia, IL

Performed stress analysis of various aircraft components and system installations using hand calculation, Femap, NEi/NX Nastran and Solidworks in support of certification of major alterations and STCs. Examples of the commodities are; Galley, Lavatory, Seat, Divan, Cabinet, PSU, Water & Waste, Oxygen Systems, Avionics components and Antenna.

Prepared documentation such as PSCP, ICA, RFC, etc. in support of STC projects.

Performed stress analysis of primary structures for various structural repairs in support of the MRO operations.

Wrote VBA program for Excel, MS word, AutoCAD and Femap. Programs include creating a whiffletree for testing of the monuments in Femap. Exporting output data from Femap into Excel and validating the output. Extracting interface loads for the monuments. Calculating stiffness data for airplane floor at seat locations and other utilities used by stress engineers.

Performed modal analysis of interior monuments, headliner, and side ledge to analyze isolator and achieve sound reduction inside cabin.

Utilized CATIA in Enovia environment to prepare solid model and design drawings for manufacturing.

Participated in certification static testing of aircraft interior monuments.

Worked with FAA Designated Engineering Representatives (DER) to obtain FAA 8110-3 approvals. Examples of major projects are: Baggage compartment installations for Boeing 737 airplane and review of structural drawings and substantiations of B787 Hydraulic Systems in support of Boeing in obtaining the Type Certificate.

Prepared certification plan and test plan for establishing FAA approved allowables of structural attachments such as click bond fasteners.

Familiar with CFR 14 Parts 23, 25, 27, 29, 91, 121 and 135.

Senior Engineer Sept.2004- Sept. 2008

Belcan Corporation, Cincinnati, OH

Worked on structural MRB, stress analysis, fatigue analysis, manufacturing support, and field support for General Electric Aircraft Engines (GE90, CF6, LM2500, LM6000, LMS100 family of engines).

Performed hand calculations and Finite Element Analysis for engine and compressor components.

Worked on nuclear power plant steam turbine test facilities project for GE in Schenectady NY.

Worked on packaging Rolls Royce gas turbines for power generation applications.

C++ and Perl programming for FADEC Test System for GE Aircraft engines

Designed test rigs.

Chief Engineer 2003-2004

Applied Engineering Ltd., Wilmington, Ohio

Performed design and stress and fatigue analysis of various aircraft component and system installations. Worked closely with FAA DER on Parts 23 and 25 aircraft.

Worked on the IPC, AMM, and FIM for DC-8 aircraft converted from passenger to freighter.

Lead Software Engineer 2002-2003

The Gem City Engineering Co., Dayton, Ohio (Contract Position)

Lead a team of three software engineers.

Analyzed, designed and implemented a distributed control system using Microsoft DCOM technology and C++ with Microsoft Visual Studio for a state of the art newly developed manufacturing tool for IBM (Hitachi). The tool consisted of National Instrument Analog DAQ cards, Epson robot, motion controllers, and I/O racks with connectivity to a mainframe database.

Senior Software Engineer 2001-2002

LexisNexis, Miamisburg, Ohio2001-2002

Developed web-based applications using C++, HTML and Java Script.

Performed OOAD for adding new capabilities to the product and performance improvement.

Reduced application response time approximately 95% (470 seconds to 24 seconds).

Software Engineer II 1998-2001

Structural Dynamic Research Corp. (SDRC), Milford, Ohio 1997-2001

The makers of the award winning CAD/CAM/CAE software (Ideas). SDRC is now UG a subsidiary of Siemens.

Designed and developed software in C and C++ using Object Oriented Analysis and design methodology through use of UML and case tools.

Developed GUI for product, adding new functionality, ease of use, and immediate graphical feedback to users.

Solved problems and performance issues with the product.

Product Development Engineer (1997-1998)

Integrated the product (Ideas) with third party software on a variety of platforms.

Developed Test Plans for new projects to ensure meeting of all requirements and deadlines.

Assured quality of software through regression testing, debugging and tool maintenance.

Plant Support Engineer 1995-1997

Lancaster Colony, Leesburg, Ohio

Designed, installed and integrated system for robotics packaging unit to detect and flag defective packages.

Saved over $1M per year by identifying and solving quality problem affecting five manufacturing lines.

Designed and installed control panels, wiring, instrumentations, and piping systems.

Initiated and investigated a computerized labeling and tracking system that saved over $200K per year.

Developed programs for PLCs and integrated them with computerized control system for robots.

Design Engineer 1991-1995

French Oil Mill Machinery Co., Piqua, Ohio

Designed special order machinery for oil milling.

Designed the complete chemical process for the turn-key solvent extraction plants.

Designed and developed piping and instrumentation diagrams, wiring diagrams, control systems, MCC, and bill of materials.

Commissioned and started new plants.

Mechanical Engineer 1989-1991

Belcan Engineering Services, Inc., Cincinnati, Ohio

Designed Chemical Processes and HVAC for pharmaceutical industry.

Mechanical Engineer 1979-1989

Tavanir Inc., Iran

Overhaul maintenance of power plants. Turbine and generator overhaul. Refurbishment and enhancement projects to improve the performance of power plants.

Education: Six Sigma Green Belt certification (2009), Villanova Online University

MBA (2008), Xavier University. Cincinnati, Ohio

MS in Mechanical Engineering (2002)

MS in Computer Science (1997)

Wright State University. Dayton, Ohio

BS/MS in Mechanical Engineering, Pahalvi University. Shiraz, Iran

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