Engineer Quality Control

Kaveh Forouraghi, Ph.D., P.E.

**** ****** ***

Bethlehem, PA, 18017

Phone: 610-***-****

Cell: 610-***-****

Email: abmela@r.postjobfree.com

OBJECTIVE: A position in engineering with interests in management, product

and process development and/or manufacturing/QA.

QUALIFICATIONS

An experienced licensed professional engineer with skills in Product and

Process engineering, R & D, Capital Projects/Justifications, Project

Management, TQM (i.e. Total Quality Management), Black Belt in Six Sigma

and SPC techniques, Design of Experiments (i.e. DOE), Root Cause Analysis,, Controls and Instrumentation, Sensors/Calibration, Stress and Thermal

analysis, Codes/Standards, and providing technical training to hourly or

salaried personnel.

Some of examples of the specific skills include the following:

o Analytical and hands-on problem solving skills

o Project Management experience in both research and industrial capital

projects

o Throughput and Productivity analysis including, stop, delay and gap

time analysis, line balancing

o Data mining/analysis and statistical techniques (e.g. Matlab, Mini-tab

and MS. Access)

o Quality Control Charts (Mini-tab)

o Instrumentation and Controls analysis (e.g. Matlab)

o Thermal and stress analysis

o Process and Product characterization (e.g. DOE Techniques)

o Product qualification and testing (e.g. Bell-Core standards)

o Excellent Communication Skills: Currently a part time lecturer at

Drexel University teaching TQM and ISO-9001 to students at Goodwin

College of Professional Studies

o Organizational skills and ability to set priorities.

o Excellent mentoring skills

EDUCATION/CERTIFCATIONS

Ph.D. Mechanical Engineering, Iowa State University,

M.S. Mechanical Engineering, Iowa State University

B.S. Mechanical Engineering, Iowa State University

. PE License: Professional Engineer License in State of Pennsylvania,

PE077672

. Black Belt Training in Six Sigma Methodology, GE Co., Baltimore, MD,

1999

. Automation Systems in Flat Rolling, International Rolling Technology

Course, Industrial Automation Systems, Inc., Edinburgh, Scotland, Fall

1996

EXPERIENCE

Technical Consultant, 2002- Present, Tin Mill Division, Severstal-NA

Steel, Sparrows Point, MD

To improve yield and productivity of the tin mill operations by providing

engineering services to the tandem mill operations, annealing lines and the

double reducing mills. Evaluate the existing rolling practices with

respect to productivity and throughput and to implement solutions to

improve these parameters. Provide technical training to both salaried and

hourly personnel. Some examples include the following:

. Perform performance monitoring, quality control and cycle time

optimization.

. Project management on upgrade projects with the benefits justification.

Lead and manage team of engineers and operators to assess the mill's

needs on the upgrades for the capital projects.

. Providing specs on automation and upgrades to process control systems.

. Provide in-house training on key process control issues to both salaried

and hourly personnel.

. Validation of on-line measurement devices (e.g. off-line on-line

comparisons).

. Calibration equipment re-design and procedure development on critical

process measurement systems

. On-line monitoring of critical process parameters such as motor speeds,

tensions, roll forces and lubrication parameters for statistical

stability and problem solving.

. Communicate technical results to a wide audience

. Analysis and improvements of complex real-time control systems used in

high-speed steel rolling processes (using Matlab).

Major Accomplishments:

As a result of the above efforts, there has been a 15-20% increase in the

productivity (expressed as tons/hour) of the continuous annealing lines at

the tin mill operations.

Adjunct Assistant Professor, 2007-Present, Drexel University, Philadelphia,

Pa

Currently a part time lecturer at Drexel University teaching principles of

Thermodynamics, Power Cycles, Fluid mechanics, Mechanics of Materials,

Total Quality Management System, TQM, Six-Sigma methodology, statistical

process control techniques, and ISO-9001 to practicing technologists

seeking engineering technology degrees at Goodwin College of Professional

Studies. The disciplines include applied mechanical, electrical and

manufacturing engineering degrees.

Member of Technical Staff, 2000-2002, Microelectronics Division, Fiber

Optics section Lucent Technologies, Allentown, PA

Managed and multi-tasked a variety of complex and time sensitive projects

in the development and commercialization of transponders used in high-speed

communication networks. Major responsibilities included the following:

. Chief FMA engineer in charge of managing a team of engineers and

technicians to optimize, perfect and commercialize the new product line.

. Manage the team of engineers and technicians to carry out the Bell-Core

qualification tests on the product design including damp heat,

temperature cycling, and pull tests and perform the necessary analysis.

. In charge of supplier Pre-qualification and their compatibility with the

standards.

. Material characterization, failure mode analysis.

. Optimization of the electronic packaging

. Trained and mentored the junior process engineers and technicians.

Major Accomplishments:

. Performed root-cause-analysis and DOE to optimize optical alignment

between the fiber and the laser and the fiber-attach process resulting in

a 30% increase in the pilot line's first-pass-yield.

. Performed root-cause-analysis and DOE to optimize the optical alignment

between the fiber and the PIN receiver, resulting in a 40% increase in

the device's sensitivity.

Research Engineer, 1995-2000, Homer Research Laboratories, Bethlehem Steel

Co.

Bethlehem, PA

Provided technical expertise to enhance the steel rolling processes of

various rolling operations at Bethlehem Steel Corporation. Responsibilities

included:

. Provide capital justification and technical plans for research and

development projects at both the manufacturing facilities and the

laboratories.

. Development and evaluation of steel rolling practices

. Design of processes, equipment and control systems

. Improve productivity, yield and product quality

Major Accomplishments:

. Provided capital justification and technical plans for a client-server

type quality diagnostic system to improve yield. Led and managed a team

of engineers and technicians to develop such a system from conception to

the finish. The capital justification itself involved a significant

effort to bring together a host of people from operations to process

control and Research to converge on the monetary and improved yield

benefits. The system which was quite novel for its time was successfully

installed and put to operation in 1997.

. Coiling defect improvements: designed and developed a new stress relief

policy providing a better and more optimized stress distribution.

Reduced the 30% failure rate due to coil collapse to less than 1% in some

of the operations.

. Development and refinement of the on-line (steel rolling) dynamic models

leading to enhanced quality

. Tuning and refinement of on-line thickness control routines with Matlab

and Simulink leading to less off-target thickness length per coil

. Well-established reputation as a successful technical leader in the

client plants

Research Engineer, 1987-1990, Ames Laboratory, Center for Non Destructive

Evaluation,

U.S. Department of Energy, Ames, IA

Research Engineer in the technology transfer program (initiated by the

Department of Commerce) to research the state-of-the-art nondestructive

testing techniques and develop and transfer them to industry. These devices

used non-contact EMAT (electro-magnetic-acoustic transducers) technology

and piezoelectric designs.

Responsibilities included:

. Set-up and testing of ultrasonic measurement systems at the laboratory

level

. Prototype development

. Signal processing and spectral analysis using FFT

. Prototype evaluation by designing laboratory experiments including

thermal, tensile and vibration tests,

. Field engineer to demonstrate the prototypes to the industrial leaders in

auto and steel industries

. Working with the design teams to design the prototypes

Major accomplishments:

. Successful development and refinement of the Phase-Slope technique used

in the prototype

. Successful evaluation and acceptance testing of the prototypes and

compatibility with FCC and OSHA regulations.

. Successful demonstration of the prototypes to the auto and steel

industries

TEACHING/EDUCATIONAL EXPERIENCE

Research Associate (Ph.D.), 1991-1995, Ames Laboratory, U.S. Department of

Energy, Ames, IA

Dissertation title: "Ultrasonic Measurement of Drawability of Low Carbon

Steel Sheets". A

collaborative research was conducted between Ames Laboratory, Ford Motor

Company, National Steel and LTV Steel. The purpose of this research was to

investigate deeper into the relationship between the crystallographic

texture of the steel sheets and their plastic properties using elastic

waves. One of the ultrasonic prototypes that had been previously developed

by this author's help was used in this study (See the Research Engineer

experience above). This prototype used non-contact electromagnetic

acoustic transducers (EMAT) technology as an alternative to the traditional

destructive techniques such as tensile tests.

Teaching Responsibilities: In charge of an instrumentation laboratory

teaching principles of measurement and instrumentation systems including

Design of engineering experiments, vibrations and feedback control, data

acquisition systems, digitizers, piezoelectric probes, strain gages,

filters, thermocouples and DC servo-motor

PROFESSIONAL SOCITIES

1. American Society of Mechanical Engineers, ASME

2. Association for Iron and Steel Technology, AIST

3. American Society for Quality, ASQ

PERSONAL INFORMATION

Married, three children

U.S. Citizen

Leisure interests: Playing Guitar, bicycling, home projects

REFERENCES

Available upon request.

Contact this candidate