Engineer Power Plant

abm08h@r.postjobfree.com Walter J. Nill CP: 810-***-****

Summary of Qualifications:

UTC Power - Systems Engineer for a PEM Fuel Cell Power Plant. My most recent

responsibilities involved the product development, documentation, testing,

reporting, as well as data reduction, plotting and analysis with both MATLAB and

Excel. I have become very proficient with MATLAB due to the volume of data that had

to be processed in a timely manner and plot types required.

The resulting plots were then utilized as a foundation for analysis of anomalies

and root cause determination. This then enabled the corrective action formulation

and implementation which could be mechanical, chemical, controls or SW in nature.

These plots were also used to demonstrate compliance to requirements.

I also performed build confirmation and checkout of the power plant in assembly by

confirming build components, placement and then actuating these through the control

system.

Delphi E&S - Instrumentation. I was Lead Product Systems Engineer performing the

duties of the Technical Team Leader leading a product design and development

engineering team. I supported all Systems Engineering functions and disciplines

while guiding the engineering team in the development task based upon intimate

knowledge of the requirements as well as keeping the Product Definition Document up

to date. The goal was successful design execution of a product exceeding the

customer requirements and on time production startup of the 2010 Volvo Collision

Avoidance Detection System (CADS) Head Up Display (HUD).

I have led the engineering team through concept design as well as done this myself

for programs.

I regularly perform trade-off analysis throughout the development cycle.

I am very proficient in DFMEA/PFMEA concepts, evaluating RPN and their rankings to

lower risk.

I expect to be involved in the entire product life cycle from initial concept to

field support.

I lead the development and documentation of test plans to verify and validate

requirements including analyzing test data, and writing test reports as well as

closing verification incidents.

I have represented Systems Engineering during internal and external meetings.

I have 10+ years in a technical role with emphasis on electrical and mechanical

systems including validation and verification testing.

I have assisted other System Engineers in managing all aspects of their projects

including development and review of requirements, requirements flow down, system

architecture, risk management, technical performance measures, testing, interface

control, cost control, program review preparation and system integration.

I am very experienced with electro-mechanical hardware (instrumentation, and

controllers)

I am very experienced in an Integrated Product Development Environment. I also have

very strong MATLAB skills.

I have a good understanding of systems engineering principles including functional

block diagrams and analysis and familiar with INCOSE standards.

My requirements management skill and experience is excellent due to the need to

assist customers in the development of specifications and flowing those into a

company document (PDD) for communication to a Product Development Team.

I am proficient with Project Management and the utilization of software to develop

and maintain schedules for deliverables.

I regularly support the Systems Engineer functions in maintaining appropriate

planning documents such as the System Engineering Management Plan, Risk Management

plan, Requirements Management Plan, Requirements Traceability Matrix, Configuration

Management Plan, System Engineering Plan.

I have supported the development of the Project Plan and supporting documents as

required.

I have identified training needs and assist in delivering training for SEMP

execution, Risk Management, equipment use, and other activities as required.

I regularly participate in peer reviews and design reviews to ensure/verify that

requirements and allocations are met for the system design. I act as approver of

the system performance specification.

I participate in peer reviews and design reviews to support system and subsystem

engineering design and development activities.

I communicate with engineering organizations and management to resolve

program/project issues.

I have coordinated, led and managed reviews for the design and development

lifecycle tracking system and subsystem. (PDR, CDR) Develop and managed

deliverables, present system engineering deliverables at the checkpoint reviews,

track all action items and deliverables through closure to ensure a successful gate

review.

I possess a very finely developed value stream analysis that begins at the

component and material choice level. This enables a very good product/system design

to co st, that utilizing DFA/DFM techniques is easy to manufacture with high

reliability.

I possess a high acumen for process thinking resulting in ease of assembly

conceptualization.

I possess strong time management, planning, organizing, interpersonal, and

communication skills.

My written and verbal English proficiency is excellent. I have studied Spanish.

I have extremely well developed PC proficiency including Microsoft Office

applications.

Experienced in systems, software, and Program Management. My Mechanical Engineering

skills are well developed and are very valuable additional skill set.

Experienced as team leader or member in multi-discipline team environment.

Professional Experience:

Systems Engineer - UTC Power PEM Fuel Cell Power plant 2009 - present

Systems Engineering support of all aspects of fuel cell power plant development

including testing, data reduction and problem resolution. Requirements

documentation from customer and flow to PD Team.

Coordinate with Mechanical, Electrical and Technology groups to optimize

performance and meet customer expectations. Demonstrate by test and data analysis

requirements met. Document and /or present findings.

Lead Systems Engineer - Delphi Corporation

2000 - 2009

Instrument Panel Clusters (IPC) and Head Up Displays (HUD)

My responsibilities as Product Systems Engineer involve leading a product team to

the successful design execution of a product exceeding the customer requirements

and on time production startup of the 2010 Volvo Collision Avoidance Detection

System Forward Collision Warning HUD.

Lead the ME, EE, SW and other team members through the product development process

with timely reviews of progress to ensure product meets or exceeds the customer

requirements and meets timing of all program deliverables.

Interpret, document (MS Word / DOORS ) and communicate customer requirements in

great detail to the product development team. This enables the team to focus upon

understanding and implementing customer requirements in a product for high

customer satisfaction and flawless launch.

Successfully implemented model year software changes to the 2000-2009 GMT360 IPC

(Chevy TrailBlazer), the 2007-2009 GMT900 IPC (Chevy Suburban/ Sierra LD Truck).

Verify products in a system including those incorporating software for

characterization against design requirements including features embedded in code,

optical and electromechanical devices and systems. This may include basic switched

inputs at various voltages or messages sent over a communication bus such as

J1850, C2 CAN or GMLAN.

Assist test groups in developing proper test procedures for validation of HW and

SW. Determine proper environmental conditions and tests to be performed on the HW.

Teardown and evaluate post test parts and lead team to resolve failures. For SW

anomalies, determine if they are legitimate by attempting to reproduce them on a

systems bench, then root cause the failure and work with the SW engineer to

resolve. Once a fix is in place re-test to ensure compliance to requirements

and that no new issues have surfaced.

Release mechanical and software product documentation for production using Change

Management. Oversee

release of electrical product documentation for production.

Analyze failures of all types whether from vehicle or validation testing,

production issues, continuous compliance

on field failures and warranty. Utilize 5-why, fishbone, Shainin and other

techniques to perform root cause analysis on issues to obtain resolution.

Implement or oversee irreversible corrective actions and re-test to ensure failure

mode has been addressed. Communicate results to management and customer.

Where optical performance is specified such as for a Head Up Display (HUD),

interpret optical design

requirements and develop a set of optics to produce the required image. Prototype

and evaluate by setting up the device in an optics lab to characterize

performance. Evaluate intensity, image look down and look over angle, projection

distance, disparity, and wavelength (chromaticity).

Procure and/or fabricate components for prototype. Assemble and test mechanically

and electrically as well as via messaging through SW.

Support PPAP of product by testing and evaluating first production articles.

Verify product memory contents.

Educated plant support personnel on product (Quality Engineers, Customer Support

Executives, Resident engineers, & technicians)

Physically support show, proto, fleet and pilot build when required. Answer

questions and facilitate changes.

Support Service Engineering as required with history of model changes,

functionality and SW change tracking.

Experienced with Class 2 and GMLAN devices and interactions - many modules on bus

Software development testing - Systems Bench checkout of new code and anomalies

Software development testing - Vehicle level checkout of new code and anomalies

Delphi Delco Electronics

1983 - 2000

Senior Mechanical Product Engineer

I have as a Mechanical Product Engineer successfully designed and launched

(concept to production) several major Instrument Panel Cluster (IPC) and Head Up

Display (HUD) programs. These include the 2000 GMX270 (NVES) (Infrared Imaging)

HUD, 2000 GMX220/310 HUD, 1996 Marine HUD, 1990 GMT530 MD Truck IPC

Use my experience in the re-use of common components to lower cost and improve

reliability. Well versed in the design and specification of molded plastic

components including high precision optics and error proofing. I have very

specific examples of creative cost savings that have benefited my programs

greatly. In the 2000MY Cadillac DeVille NVES HUD, I was able to concept an optical

and lighting solution that removed $100/asm of thermal protection componentry.

This resulted in an annual savings of $100 x 10,000/yr = $1,000,000 annually. The

product ran for 4 years in this configuration yielding a cost savings total of

$4,000,000; another example of cost reduction was the removal of a very high cost

vacuum fluorescent display (VFD) and its associated power supply and support

electronics from an IPC by performing the function with LEDs. This saving was

approximately $0.36 and was applied to 350,000 vehicles annually for 4 years. The

savings were $0.36 x 350,000 x 4 = $504,000.

From initial concept, design the mechanical aspects of a product to comply with

geometry, electrical, thermal, appearance, lighting, touch (ergonomics) and HMI

requirements. This includes all aspects of EBOM development, DFMEA and cost

considerations, material and process choices and product labeling. Utilize PFMEA,

DFA, DFM and PML site knowledge to control costs and enhance quality.

Incorporate GD&T to control tolerances in components and the assembly. These

would support meeting the requirements of the product mounting point interfaces as

well as component mating in the assembly.

Specify metal stampings, the material and temper and any coatings required.

Specify springs and the material and temper and any coatings required. Specify

fasteners including material and temper and any coatings required. Also calculate

the proper installation torque backed up by empirical data.

For every plastic component of the design, ensure geometry meets functional

requirements. Ensure resin choice considers thermal, chemical resistance,

finishing, texture and cost objectives. Utilize mold flow analysis for part fill

given geometry and resin choice. Consider tooling requirements for successful part

molding such as wall stock thickness, draft, and material savers to reduce sink

marks. Consider features that cause undesirable affects (sink or flow marks) on

first (visible) surfaces.

Education:

Bachelor of Science in Mechanical Engineering

Michigan State University East Lansing, MI

Concentration on materials engineering including plastics.

Continuing Education in Systems Engineering graduating in 2000.

Certified as Systems Engineer November 2000.

Ongoing training in various areas such as Quality Engineering, Six

Sigma, Documentation systems including DOORS, Green Belt, Electronic

cooling and durability, etc.

Additional training in fuel cell theory, technology, design and

production at UTC-Power 2009

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