Engineer Design

Paul P. Coker **********@*********.***

310-***-**** Palo Alto, CA 94301

http://www.linkedin.com/in/paulcoker4concept2launch

Mechanical Engineer / Systems Design

Innovative, ground-breaking solutions from deep understanding / broad experience

15+ years hands-on with critical aerospace (vehicle, ground station) and medical systems

Analysis, design and project management

Specification creation, allocation, tracking

Team lead / training / presentations

Process design

Thorough and imaginative with a big picture perspective

CLEARANCE: Secret with SSBI and Polygraph (25 Sept. 2009)

Design

Paradigm-shift 72x improvement in Time-To-Repair achieved for a 3 Megawatt pulse

radar system with unique system architecture (required facility mods, anticipated customer

priorities). Performed detail and assembly design for same and for a multi-kW tube test

station. [ETM Electromatic]

Compressed concept-to-delivery cycle 67% for 3-axis vibe sensing package. Designed

assembly that allowed concurrent, independent design/fab of power conditioning, analog

board and digital board, which were integrated for proto-qual, delivery. Also designed

gyro sensor package and antenna deployment mechanism. [Boeing (satellites)]

Coordinated with 7 different design groups to fashion digitally controlled

electromechanical system architecture, merged seamlessly with interfacing designs

(ISS airlock pressurization system, now on-orbit). [Boeing (space station)]

Saved 33% of unit cost in design of 3-vaporizer aneasthetic controller (was two) --

original details simplified during redesign to avoid increased cost from increased

complexity. 23x increase in pass rate, surgical anesthesia bellows (previously failed over

95% of trials). Analyzed gas dynamics of design, introduced inexpensive modification of

one component, trained assemblers. [Puritan-Bennett]

Analysis

Achieved 50% more power capacity (satellite power control unit) while decreasing

mass 20%; devised PWB design concept that maximized solid-solid heat transfer for

board mounted components. Performed vibration, stress, thermal analysis using

FEA/GEA. [Loral/Space Systems]

Performed radiation shielding/exposure analysis and multi-load case stress analysis for

amplifier oil-immersion tank. [ETM Electromatic]

Detailed FMECA for ISS airlock (digraph analysis). Nastran, AutoSEA (stress, vibration)

analysis; developed original analysis method for intermediate vibrations between FEA &

SEA ranges. Predicted previously unknown vibration sources from design analysis, later

confirmed by on-orbit observation. Numerical analysis of pressure equalization and

venting timelines. [Boeing (space station)]

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Paul P. Coker

**********@*********.*** 310-***-****

Team Lead

Coordinated design and assembly as Lead Mechanical System Engineer for 3 Megawatt

ground station radar amplifier system. System included preamplifier and control racks, oil

immersed final stage. [ETM Electromatic]

Achieved mission critical on-orbit vibration control. Assembled, led world-class

engineering team to predict/suppress operating vibration. Led Airlock depress/repress

system development; designed architecture, guided layout, wrote specs and conducted

key component bid process. [Boeing (space station)]

Saved $266K+ annually by leading process improvement efforts as chair of EI

teams. [Boeing (satellites)]

Organized and coordinated programs of church with $500K annual budget as volunteer

VP of Programs. [UUCPA, Palo Alto CA]

Project management

Planned and led tube test system design/build (met schedule and budget targets). [ETM

Electromatic]

77% compression of concept-to-delivery cycle for harness connection adapter.

Used digital model "prototyping", produced drawings, expedited in-house

fabrication. [Loral/Space Systems]

Specification Creation

Redefined unproduceable mission critical specification (vibration output allowance for

ISS), adopted by NASA without alteration. [Boeing (space station)]

Suppressed 87% of anticipated cost increase (refrigeration requirement added to ground

station) as refrigeration Contract Technical Monitor (saved $70K per system) without

quality compromise. Authored spec which allowed design flexibility, led source search,

conducted competitive bid, performed technical monitoring. [ETM Electromatic]

Specification Allocation / Tracking

Saved $94K by allocating leakage spec to component level in 3 days (typical 3 months).

Devised original schema/methods, specified all thru-hull components/mechanisms.

Training / Presentation

Received accolades for best segment in Critical Design Review from Deputy

Associate NASA Administrator for Space Station, ISS WP2.

Presentations / briefings of all kinds to management and customers at all levels.

Trained colleagues, Quality and Operations personnel in new and revised processes.

[Boeing (satellites)]

Facilitated workshops, organized and led team of facilitators, as volunteer co-

lead. [ProMatch, Sunnyvale CA]

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Paul P. Coker

**********@*********.*** 310-***-****

Process Design

22x productivity increase, medical assembly line (restructured line, rewrote

procedures). Resolved issues in two weeks, full management target achieved in two

months. [Puritan-Bennett]

Brought new IT system on-line (Receiving Inspection) without delays or disconnects.

Redesigned/consolidated diverse processes into unified Lean process that matched

new system structure and parameters. Performed root cause and corrective action

determinations in-house and at suppliers. [Boeing (satellites)]

Developed processes for new infrastructure and strategic process improvement as part

of path-finder team. Performed root cause and corrective action determinations.

[Loral/Space Systems]

ANCILIARY SKILLS

Design: Pro-E, Unigraphics/UG-NX3, AutoCAD, Catia Cadam

Analysis: Mechanica, Patran/Nastran, AutoSEA (stress, vibration, thermal, kinematics)

Other 2D/3D: ProductView, VisView, Canvas, Visio

Business/IT: Project, Word, Excel, Power Point, Access, Visual Basic for Applications

EDUCATION

Bachelor of Science Engineering, University of California, Los Angeles

[Engineering Systems Department]

Graduate Certificate, Loyola Marymount University, Los Angeles

[Systems, Quality & Lean]

DATES OF EMPLOYMENT

The Boeing Company Senior Staff Engineer

2001 To 2011

Space Systems/Loral Sr Engineer Specialist

1998 To 2001

ETM Electromatic Lead System Engineer

1995 To 1998

Pacific Scientific Co. Design Engineer

1994 To 1995

The Boeing Company Engineer Specialist

1984 To 1993

Puritan Bennett Corp. Design Engineer

1981 To 1984

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