Louis J. Liguore

*** *. **** **. ******, Ohio 445**-***-***- 4430 abnjob@r.postjobfree.com

Professional Profile

Creative master’s-level Engineer known for strong analytical skills and the application of sound research

methodologies to assess needs, identify alternatives, and recommend strategies that facilitate solving difficult

engineering problems. Areas of expertise include control system design and implementation, instrumentation,

product and process development, the analysis, design and implementation of electro-mechanical devices, and

servo systems.

Skills Summary

Software Development: Problem-Resolution/Debugging: Project Management : Communications:

Embedded Control Development and Programming: Test Automation: Data Acquisition

Professional Experience

Delphi Automotive Systems, Warren, OH

1984 – 2009

Senior Project Engineer, Advanced Engineering

Developed new products, processes, and automated assembly, testing, and monitoring equipment for a leading

global supplier of mobile electronics and transportation systems

Selected Accomplishments

Control System Design and Implementation, Process Development, Servo Control, Software

Development, Electro-Mechanical Design/Analysis

- Developed the control system for a machine that allows the insertion of very small terminals into

connectors, including verification of proper insertion. The development effort included the system

architecture, hardware, software, motion control, and a signature analys is system. A patent is pending for the

development of the Terminal Insertion Signature Analysis System. [Automatic Wire Plugging Machine]

Increased mandrel production by 1125% over the original machine with improved quality for the Gold

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Dot connection system. Developed the hardware and software to produce mandrels, and developed a unique

Dimpling Head. Production took place at PHI Irvine California. I was awarded a Trade Secr et for the PHI

Dimpling machine technology that allowed very close centerline dimples to be produced without damaging

adjacent dimples. [PHI Dimpling Machine 1 & 2]

- Improved the quality of the Fuse Loading process by developing two generations of automatic fuse loaders

to position fuses into holders prior to insertion into Fuse Blocks. Production took p lace at two Alphabet

plants in Indiana for eight years. [Fuse Loader 1 & 2]

Test Automation, Data Acquisition, Servo Control, Software Development, Project Management

- Increased Wire Flex Testing productivity 1200% over the existing method by developing a control system

architecture, hardware, software, and motion system. There are six systems in production with hundreds of

billions of cycles flexed. I received a Meritorious Submission Award from the Delphi Patent Committee for

leading the development of this very novel Wire Flex Tester System. [Wire Flex Testers]

Coordinated an international development project to use an Italian supplier’s machine vision system to

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verify the application of a coating developed at Delphi Michigan that was being applied to a flex circuit

product produced at Delphi Germany. In addition, I was responsible for control system architec ture,

hardware, software, motion system. [Flex Circuit Inspection System]

Louis J. Liguore 330-757- 4430 Page 2

Problem Resolution/Debugging, Electro-Mechanical Design/Analysis

- Saved $850,000 by designing a machine to sort 5 million, potentially out of specification, ROM Keys at a

rate of 3 seconds per inspection. The project was completed in 6 weeks including the prototype build. The

systems capability was proven with statistical techniques. Two additional machines were fabricated. All of

the parts were inspected with no customer complaints. [Rom Key Inspection Station]

- Reduced scrap from 22% to less than 1% on five Anti-lock Brake System harness production lines by

identifying and quantifying the causes of the scrap and implementing the improvements across the five

production lines. [ABS Lines Scrap Reduction]

- Saved millions of dollars of plastic per year by reducing variation in the sample preparation for Minimum

Cable Wall Gauging. Reducing measurement uncertainty allowed the cable wall to be produced closer to the

minimum specification. [Minimum Cable Wall Gauging]

Embedded Controller Development and Programming, Communications

- Improved quality and productivity of the Tuning Fork by Male Terminal Insertion stations by leading an

embedded Micro-Controller development project to monitor the terminal insertion force. Monitoring the

terminal insertion force allowed the detection of cracked or broken wires resulting from the terminal insertion.

[Tuning Fork by Male Insertion Force Monitoring System]

Product and Process Development, Servo Control, Software Development

- Led development of the hardware, software, and motion system for the Saturn Bussing Plate Processor .

Fifty machines were produced. Production took place at Ohio, Mississippi, Mexico, and Korea. I was

awarded a patent for development of Non Rotating Head Technology. [Saturn Bussing Plate Processor]

- Created a new product line and the fully automated production system to produce Junction Blocks for the

Cadillac EK, and Buick Regal. Implemented a production running change, replacing manually produced wire

wrapped Junction Blocks with the automated production of routed wire Junction Blocks. No product failures

were ever traced to the Junction Blocks in the entire production run. I was awarded 2 Patents associated with

the development of the Bussing Plate product and process. [Junction Block Processor]

Engineering Honors and Certifications

Inducted into the Delphi Innovation Hall of Fame

Inducted into the General Motors Engineering Hall of Fame

Recognized by Hughes Space and Strategic Product Operations

Awarded 3 Patents, 1 Trade Secret, and 1 Patent pending, 3 active Record of Inventions

Six Sigma Green Belt and Shainin RedX Journeyman

Education

Masters of Science, Mechanical Engineering, Youngstown State University, Youngstown, Oh

Bachelor of Engineering, Mechanical Engineering, Youngstown State University, Youngstown Oh

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