Terry (Tee) Thomas

**** ** ********** **. **** Springs, MO 64014

Home: 816-***-**** Cell: 423-***-**** abi11o@r.postjobfree.com

Engineer

Selected Accomplishments

. As Technical Lead, within four months after taking over project that had

stalled for two years at 10% completion, took project to 60% completion

through building a consensus within the design team and helped facilitate

the completion of the working prototype through technical direction. (ATK

- 0.50 cal Core Feed)

. As Technical Lead, took initiative and leadership in defining areas of

technical issues and helped with manufacturing process changes that

resulted in an accurate end-product (ready for manufacture) compared to

print. (ATK - Cold Heading Green (lead free) M855LF Penetrator)

. Within nine months redesigned existing $3 Million machining operation

operating at 35% efficiency for three years to consistently operating

85%+ (on average) and 98% peak efficiency. (Alemite)

. Reduced labor cost by $350,000 a year and decreased downtime by 90%

through redesign of mechanical components to extend component lifetime.

(Alemite)

. Improved process from 60% to 80% while decreasing scrap by 70% through

fixture redesigns and streamlining workflow. (Kingston Timers)

Skill Set

Project Management Mechanics of Materials Innovative

Government Contracts Cold Header Tool Design Analytical

Military Standards Vision Systems Creative Problem Solver

SAE Aircraft Standards Hydraulics & Pneumatics Team Oriented

Specialty alloys (Monel, Computer Programming World Class Customer

Inconel..) Service

Professional Experience

11/2007 to Present - ATK Armament Systems, Independence, MO

The world's largest manufacturer of military ammunition and integrated

medium-caliber gun systems.

Project Engineer II, Research and Development (Design), Government

Clearance

Selected Accomplishments:

. Within three (3) weeks, fixed two month long vision system problem with

not catching rejects and giving false rejects with a savings of $600K in

good product loss.

. Successfully brought in $1.2M new government business by writing a

government proposal for Broad Agency Announcement requests for aluminum

5.56mm case proposal.

. Saved significant amount of time (from 48 hours to 4 hours) in FEA stress

analysis of metal components through finding a customized metal forming

FEA analysis software.

. One of six person team to write quality procedures of Engineering Stage

Gate Lean Enterprise System to obtain ISO9001 certification for the

Research and Development department.

Technical Lead - Project: 0.50 cal Core Feeding

. Led review meeting for project to the executive board and managers,

conducted meetings assigned tasks and deadlines.

. Worked closely with manufacturing and management to develop system

requirements.

Technical Lead - Project: Cold Heading Green (lead free) M855LF Penetrator

. Wrote statement of work for work required and expected deliverables by

suppliers. Worked with purchasing and Supply Chain Manager and led

meetings with suppliers and established goals and action items.

. Helped to ensure successful prototype sample lot of full geometric

compliance with existing print using formed penetrators. Developed

customized alloy optimized for performance and manufacturability.

Test Coordinator for 7.62mm lead free ammunition project - Wrote test work

instructions, scheduled and monitored testing, analyzed data and wrote

formal reports in easy to understand format with recommendations.

5/98 to 11/2007 - Alemite Corporation (Lincoln), Johnson City, TN

Premier company for automotive lubrication and fluid handling systems

world-wide.

3/01 to 11/2007 - Senior Research and Development Engineer (Design)

. Project management on new product designs. For example: suitability of

aircraft grease fittings to meet government specifications.

. Personally responsible for $125K cost reductions by eliminating

unnecessary parts and making material changes.

. Interacted with customers on daily basis to answer questions and

provide product support.

. Project responsibilities from initial product conception, budgeting,

prototyping, testing through working with manufacturing to ensure new

products or product redesigns are easily manufactured.

. Eliminated $100K operating costs in washing parts by replacing with oil

bath.

. Solved customer needs for customized vent fitting applications for

axles.

. Reduced costs of hydraulic pump by replacing component materials that

led to reducing lead time by ~ 80%.

. Identified and removed unnecessary accessory components to hydraulic

pump assembly, which further reduced costs by $180K per year.

. Redesigned established product to achieve a non-drip nozzle for

automated oil dispensing, which resulted in resolution of customer

issues with customer feedback of "one thing that was well redesigned"

and "met our needs."

. Designed innovative portable pneumatic grease gun with applications

including hazardous location use.

. Equipped hydraulic hose reel for European sales, which are anticipated

to increase the market by 30%.

. Invented a leak proof zerk fitting and designed improvements to a

hydraulic track tensioning fitting.

5/98 to 3/01 - Senior Manufacturing Engineer

. Well versed in Six Sigma, Lean Manufacturing and Kiazan.

. Vision Inspection Systems

. Project Manager: Vision System Assembly Machine Improvement ($200K

budget).

. Designed numerous computer-testing systems including electrical

schematics and programming of data acquisition systems.

. Designed automated vent fitting test system including electrical

schematics, which reduced set up times by one hour and eliminated the

need for technician.

. Successfully programmed and designed automated vision inspection system

including statistics with a test rate of 435 milliseconds with 16

measurement inspections.

4/97 to 5/98 - Manufacturing Engineer

Sturdy Corporation, Wilmington, NC

Automotive and marine manufacturer of intake manifold runner control, OEM

automotive governors and IMRC with ~200 employees.

< QS900 internal auditor, wrote process FMEAs, process instructions and

taught ergonomic classes.

12/95 to 4/97 - Electrical Motor Manufacturing Engineer

Kingston Timer, Smithville, TN

Washing machine and dryer timers manufacturing company with ~500

employees.

. Responsible for bringing one million-dollar switch automation machine

online.

. Developed 250,000K automated parts washer.

11/90 to 12/95 - Process Engineer

Robert Shaw, Cookeville, TN

Industrial and automotive manufacturer of thermostats, throttle position

sensors, industrial level sensors and accelerometers with ~1000 employees.

. Head engineer for industrial controls department, and engineer for

throttle position sensor.

. Designed and programmed automated computer test equipment and data

acquisition systems.

Education

MBA, 2003 (GPA 3.6), King College, Bristol, TN

MS Mechanical Engineering Courses 1993 - 1994, Tennessee Tech,

Cookeville, TN

BS Aerospace Engineering 1990, University of Tennessee, Knoxville, TN,

EIT 1990 Number: 13411

Computer Proficiency

Software: Generic CADD AutoCAD 2007 MS-Project Manager

Solidworks 2007 Cosmos Pro E Cadd

Software

Programming Siemans PLC Labview

programming

Languages: Cognex Checkpoint CNC

v 9000

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