Engineer Six Sigma

Thomas R. Frederick

*** ****** **., **** *******, CO 80525

******@*********************.*** 970-***-****

SUMMARY

Senior level mechanical engineer with BSME and extensive experience in the

design and development of industrial and aerospace products:

. New Product Design, Development and Analysis

- Electro-Hydraulic and Electro-Mechanical Actuators and Systems

- Electro-Hydraulic and Electro-Mechanical Servovalves

- Process Control Valves

- Flow Systems (Liquid and Gas)

. Dynamic System Modeling & Simulation (Simulink, ACSL, Hysan)

. Test Plans for Development, Validation, and Production

. COTS Component Selection & Specification

. Mechanical Component Design & Analysis

. FEM Analysis (ANSYS)

. DTC, DFM, DFA, DFSS (Design for Six Sigma) Statistical Tolerance Design

. Geometric Dimensioning & Tolerancing (GD&T) per ANSI Y14.5

. Six Sigma Black Belt Projects

EDUCATION

BSME, with distinction (GPA 3.9/4.0) 1987

Cornell University, Sibley School of Mechanical and Aerospace Engineering

Ithaca, NY

EXPERIENCE

Frederick Group Inc., Fort Collins, CO 05/2004 - Present

Consulting Engineer: Provided complete conceptual new product designs for a

family of water injection flow systems for small Siemens (Alstom) and Solar

turbines:

. Researched system requirements (e.g. flows, pressures, & temperatures for

all operating conditions and working environments) and documented with

system specification

. Created schematics and simulated functional operation

. Performed trade studies to determine minimum number of family members &

parts

. Researched components (e.g. pumps, motors, variable-frequency drives,

control valves, safety valves, piping, tubing, instrumentation) and

created preliminary bills of materials

. Created 3D layout model of all components, piping and structural elements

Supply extensive background for the engineering design of a servo valve

component

Serve as Chief Engineer for high-end audiophile acoustic treatments, see

acoustic engineering portfolio at http://www.PerformanceAcousticsLabs.com

Woodward Governor Company, Fort Collins, CO 11/1999 - 05/2004

Senior Engineer: Technical team lead and development engineer for liquid

fuel systems, liquid & gas fuel control valves, electrohydraulic valve

positioners, electrohydraulic inlet guide vane actuators, and servovalves

for gas turbine engines including W501F, W501G, V-Machines, 6FA, 9E, and WR-

21 along with Westinghouse steam turbines

. Responsible for proposals and presentations to customers; requirements

definition and specifications with customers; conceptual design; FMECA;

modeling & simulation; stress analysis; concurrent engineering; supplier

selection/development; materials and special process selection and

development; detail design including DFM, DFA, DTC, DFSS (design for six

sigma); GD&T per ANSI Y14.5; checking; design review; prototype and first

article manufacturing and inspection; validation test planning and

execution; manufacturing engineering; technical support; MRB & CAB; and Six

Sigma Black Belt projects

Raytheon Aircraft Montek Company, Salt Lake City, UT 06/1995 - 11/1999

Senior Engineering Specialist: Chief engineer for the Atchley Controls

line of jet pipe electrohydraulic servovalves for applications on CFM56,

PW4000, IAE V2500, GE90, F/A 18E/F, helicopter, shipboard, lumber, rubber &

steel mills, underwater ROVs, motion simulators, plastic molding machines,

and other specialty fields. Leadership of up to 9 engineers and technicians

in product line technical support and the entire development process of the

new Model 800-series direct-drive (electromechanical-drive)

electrohydraulic servovalves

. Responsible for proposals and presentations to customers; creative trade

studies of new systems and concepts; modeling & simulation; project and

resource planning, scheduling, assignments and reporting; development,

qualification, and acceptance test procedures; FMEA; conceptual and detail

design, concurrent engineering, supplier selection/development; materials

and special process selection; detail design; GD&T per ANSI Y14.5;

checking; design review; prototype and first article manufacturing and

inspection; hands-on development and qualification testing; technical

support to all departments and customers; MRB; ISO 9001 implementation

Moog Controls, Inc., East Aurora, NY 07/1987 - 04/1995

Systems/Project Engineer: New product design and development of

electrohydraulic systems and components for a wide variety of industrial

applications; Patent No. 5,244,002

. Responsible for technical requirements development for new markets;

technical proposals to marketing and customers; conceptual design;

analysis, modeling & simulation; concurrent engineering; detail design;

GD&T per ANSI Y14.5; checking; development and production testing and

documentation; model shop and development lab; technical support to all

departments and customers; MRB; ISO 9001 implementation

Product Applications Engineer: Supported all aspects of product and

applications engineering of two-stage mechanical feedback nozzle-flapper

EHSVs (electro-hydraulic servo valves)

. Responsible for interpretation of specifications; modeling & analysis,

detail design and analysis of parts and assemblies; tolerance studies; PDM

(product data management); writing of assembly & test specifications;

technical support to all departments and customers; MRB

Delco Products Div., General Motors Corp., Buffalo, NY Fall 1985 & Summer

1986

Manufacturing Engineer: (Co-op) HVAC electric motor manufacturing and

facility planning

TRAINING

Six Sigma Black Belt, Air Academy Associates, 10/2003

Six Sigma Green Belt, Air Academy Associates, 5/2003

Introduction to ANSYS, JLR The Engineering Solutions Company, 3/2002

Design for Six Sigma, Successful Statistics, 9/2000

CORE Training, E-Systems, 10/1995 through 9/1998

Management Skills Workshop, Avraham Goldratt Institute, Instructor Deborah

Smith, 8/1998

Industrial Hydraulic Technology, Raytheon Aircraft Montek Company, 5/1998

Project Management (Critical Chain), Avraham Goldratt Institute, 2/1998

Project Management (Theory of Constraints), Avraham Goldratt Institute,

10/1997

Structured Workteams, Performance Resources Incorporated, 3/1997

Statistics, DOE & ANOVA, Moog Inc. and Canisius College, Prof. Dietrich

Kuhlmann, 12/1994

Electrostatic Discharge (ESD), Moog Controls, Inc., 10/1994

MIL-STD-2000A Soldering Technology & Certification, EPTAC, 7/1994

Management ... Leadership Role, Fred Pryor Seminars, 11/1993

ANSI Y14.5 GD&T Training, Moog Controls Inc., using SAE curriculum, ca.

1992

... Intrinsically Safe Instrumentation ..., MTL Incorporated, 9/1989

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