Bryan Gene Chuba

**** ********* **** – Apt. ***, Lewisville,TX 75067– 864-***-**** – ac0lqp@r.postjobfree.com

SUMMARY:

Accomplished Lead Design Engineer with 20+ years of experience in machine design, product development and testing with diversified background in Aerospace/Automotive, Product and Military/Marine Systems.

Strong background in “cradle-to-grave” design, layout, and detail for products, tooling/fixtures and special machinery; proven track-record in R&D, reverse-engineering and creating manufacturing prototypes.

Well-versed in a wide array of Machine Design, Electro-mechanical component & product design, Electrical packaging & enclosures, Hydraulic components, Piping systems, Mechanisms, Automation/Robotic, Sheet metal fabrications, Castings, Plastics,Machined components, Weldments, Machinery Arrangements and Systems.

Hands-on experience in creating BOMs & Routings, ECO’s, Design Change Requests, Material & Documentation specifications, Manufacturing Work instructions, Test Plans, Failure Analysis reports, PPAPs, PFMEA, DFMEA, Cost analysis & estimation- quoting, conceptual layout development.

CAD expertise (2D & 3D modeling, assemblies & drawing) in Pro-E CREO 2, Autodesk Inventor Pro, Catia V5r19, UG NX7.5, SolidWorks 2010/17; PLM experience in Vault, EPDM, Teamcenter – Smart Team

Six-Sigma Greenbelt and CAD Administrator certifications; ability to communicate both orally and written, works well in a team-oriented environment, high integrity to focus on customer needs, and willing to support in problem-solving to achieve follow through and eager to learn with a “positive” attitude.

TECHNICAL & COMPUTER SKILLS:

Autodesk Inventor Pro v09 up to 2015 [9600 hrs]

AutoCAD 2014 [15,000 hrs]

Pro-E Wildfire 5.0/CREO 2.0 [5000 hrs]

Catia V5r19 [8000 hrs]

UG NX 7.5 [4000 hrs]

Solidworks 2010/17 [9600 hrs]

MS Word, Excel, Project, Access, Adobe Acrobat, PowerPoint, Outlook, Visio, Microstation

FEA Analysis - Stress Analysis/ Ansys

GD&T ASME Y14.5M-1994

ASME, ANSI, Mil Standards, ISO 9000, ISO 9001, AS 9000, AS 9001, IEEE & NEMA specifications

SPC, DFMEA, PFMEA, MRB

Lean Manufacturing, 5S, Kaizan & Kanban

VAULT, SMART TEAM and EPDM Configuration Management database systems

SAP and ORACLE material database systems

DOD Std 100, 1000

APPLICATION AND FUNCTIONAL EXPERIENCE:

Cradle-to-Grave Design, development & prototype

Tool and Die Design

Jig and Fixture Design

SLA-FDM Prototype Design

Test Equipment Design

Finite Element Analysis

CAD design 3D & 2D modeling Parametric, Non-Parametric and Constraint

Machine components

Mechanical and Piping Systems / Arrangements

Electro-Mechanical Control Actuation Systems - Linear, Hydraulic, Pneumatic

Hydraulic and Pneumatic Systems

Aluminum, Stainless Steel, Alloy Steel

Sheet Metal Fabrication, Material

Plastic [Injection molding] – Vaccum Form

Automation design/development

Sustaining Engineering

Test Engineering; Component level testing,

Unit-ESS-ATP-QUAL testing,

Shock/Vibration testing

Destructive Validation testing [DOE]

Generate Test Procedures/Reports

Liaison with Vendors/Supplier, OEM customers and Government Agencies

Project Management and scheduling

PROFESSIONAL EXPERIENCE:

Revolution Retail Systems, LLC, Carrollton TX June 2015 – Apr 2017

Mechanical Systems Design Engineer

Responsible for mechanical design of Smart Cash Machines that were Bulk Coin Recycler [BCR] and Bulk Note Recycler [BNR]. Devices include injection molded plastic parts, sheet metal enclosures, printed circuit boards and machined parts.

Work with multi-disciplined team that included electrical engineers, software engineers, industrial design, purchasing, and manufacturing.

Design products according to American and International Standards and Conformity Assessment.

Create 3D and 2D models, designs, assemblies, details, weldment, installation drawing and BOM packages.

Utilize Fabrication, Machining and Welding with various stainless steel [300 series] CRS steel, sheet metal and aluminum alloy [6000 series], mechanisms and hardware, plastics – components.

Design new tooling fixtures for machining and testing.

Design and build Prototypes for System Unit – Acceptance and Qualification Testing

Create customer conceptual design packages for PDR and CDR.

Write and incorporate Engineering Change Orders [ECO’s].

Perform Cost estimates – quotes and conceptual layout development.

Perform Failure Analysis, FEA’s [Finite Element Analysis]

Perform Simulation Analysis

Interface with vendors, suppliers and customers [OEM’s]. – Domestic and International

Travel – Domestic and International

Utilized SolidWorks Pro 2017

Stewart Systems Baking LLC, Plano, TX July 2014 – Apr 2015

Systems Design Engineer

Mechanical /Electro-Mechanical design of automated specialty machines, robotics, machine design components and systems; actuators and automation components for robotics, work cells and conveyor/material handling systems for the Food, Baking, Packaging and Manufacturing Industry.

Responsible for design, development and process of automated specialty machines, robotic work cells, conveyor and material handling assemblies utilizing various materials.

Create 3D and 2D models, designs, assemblies,details, weldment, installation drawing and BOM packages.

Write and review all reports related to part numbering system, configuration management plans/procedures.

Utilize Fabrication, Machining and Welding with various stainless steel, sheet metal and aluminum alloy [5000, 6000, 7000 series], mechanisms and hardware, various Food Grade plastics – components.

Create customer conceptual design packages for PDR and CDR.

Write and incorporate Engineering Change Orders [ECO’s].

Perform Cost estimates – quotes and conceptual layout development.

Perform Failure Analysis, FEA’s [Finite Element Analysis]

Interface with vendors, suppliers and customers [OEM’s].

Travel

Utilized Autodesk Inventor Pro 2014 – Solidworks 2014

Q Automation, Derby, KS June 2013 – June 2014

Senior Principal Design Engineer

Mechanical /Electro-Mechanical design of automated specialty machines, robotics, machine design components and systems; robotics weld cells and conveyor/material handling systems for the Food, Military, Packaging and Manufacturing Industry. Designed various machine/mechanical components, weldments and fixturing .

Responsible for design, development and process of automated specialty machines, robots, weld cells, assemblies utilizing various materials.

Create 3D and 2D models, designs, assemblies,details, weldment, installation drawing and BOM packages.

Write and review all reports related to part numbering system, configuration management plans/procedures.

Utilize Fabrication, Machining and Welding with various stainless steel, sheet metal and aluminum alloy [5000, 6000, 7000 series], mechanisms and hardware, plastics – components.

Design new tooling fixtures for machining, welding and testing.

Create customer conceptual design packages for PDR and CDR.

Write and incorporate Engineering Change Orders [ECO’s].

Perform Cost estimates – quotes and conceptual layout development.

Perform Failure Analysis, FEA’s [Finite Element Analysis]

Interface with vendors, suppliers and customers [OEM’s].

Travel

Utilized Solidworks 2013/14 - Inventor Pro 2013/2014

Patriot Technical Services, Nashua, NH [contractor] Sept 2011 – June 2013

Design Engineer – Air Methods Corporation, Englewood, CO

Mechanical /Electro-Mechanical design of complex aerospace aircraft components and systems onto new and existing commercial/military helicopter airframes. Designed various machine/mechanical components .

Responsible for design, development and process of airframe assemblies utilizing sheet metal fabrication.

Create 3D and 2D models, designs, assemblies, installation drawing and BOM packages.

Write and review all reports related to avionics, mechanical systems on the aircraft to include the stress and load analysis, weight and balance, system safety hazard analysis, and test plans/procedures.

Perform Liaison Engineering – aircraft system and modification checks.

Utilize Fabrication, Machining and Welding with various stainless steel, sheet metal and aluminum alloy [5000, 6000, 7000 series], mechanisms and hardware, plastics – components.

Design new tooling fixtures for testing.

Create customer conceptual design packages for PDR and CDR.

Write and incorporate Engineering Change Orders [ECO’s].

Perform Cost estimates and formal quotes

Perform Failure Analysis, FEA’s [Finite Element Analysis], Thermal and Heat Transfer calculations

Interface with customers [OEM’s].

Utilized Solidworks 2013 - Inventor Pro 2012

Systems Design Engineer – SELEX Systems Integration, Overland Park, KS

Responsible for mechanical design/development from concept, prototype and implementation of the electromechanical packaging of hardware for surveillance radar systems.

Utilize Fabrication, Machining and Welding with various stainless steel, sheet metal and aluminum alloy [5000, 6000, 7000 series], mechanisms and hardware, plastics – components.

Design new tooling fixtures for testing and Assembly stations.

Create 3D and 2D models, designs, assemblies, drawing and BOM packages.

Create customer conceptual design packages for PDR and CDR.

Write and incorporate Engineering Change Orders [ECO’s].

Perform Cost estimates and formal quotes

Perform Failure Analysis, FEA’s [Finite Element Analysis], Thermal and Heat Transfer calculations

Perform Unit, Acceptance and QUAL Tests; develop and write Test Reports.

Interface with customers [OEM’s] such as ITT Electronics, FAA, Europe and TIER 1 Suppliers.

Utilized Inventor Pro 2012

Design Engineer – Porticos – Electrolux, Charlotte, NC

Responsible for mechanical design/development from concept, prototype and implementation of hardware and accessories for various vacuum cleaning systems.

Design/develop “new” hardware and accessories for the next generation products utilizing plastics.

Create 3D and 2D models, designs, customer conceptual, assemblies, drawing and BOM packages.

Utilized UG NX 7.5

KIMURA Inc. Material Handling / Packaging, Laurens, SC Oct 2010 – Aug 2011

Lead Product Design Engineer

Responsible for mechanical design/development from concept, prototype and implementation of packaging and material handling developed from mild steel [CRS], A36, alloy and stainless steel for the automotive and manufacturing industry.

Design/develop material handling packaging systems utilizing conveyors, 2WS/4WS Dollys, Carts.

Utilize Fabrication, Machining and Welding with various steel, sheet metal and structural steel, aluminum alloy – 6000 Series, mechanisms and hardware, plastics – components.

Design new tooling fixtures for welding [MIG, TIG and Robotic].

Create 3D and 2D models, designs, assemblies, drawing and BOM packages.

Create customer conceptual design packages and layout development. – Cost estimation/formal quotes.

Write and incorporate Engineering Change Orders [ECO’s].

Interface with customers [OEM’s] such as Toyota of America, BMW, Volkswagen, Ford, Caterpillar, and TESLA other automotive venues and TIER 1 Suppliers.

Utilized Solidworks 2010 – 2011 and CATIA V5 r19.

TIMKEN Aerospace (contract Davis IT & Engineering), Lebanon, NH Dec 2009 – Sep 2010

Product Design Engineer

Responsible for mechanical design/development of ball, cylindrical roller and split inner bearings used in mechanical applications e.g. gear-boxes, rotary components, landing gear, actuators, and engines for Commercial/Military aircraft. Designs developed from mild steel [CRS], stainless steel and bronze.

Utilize Fabrication, Machining and Welding with various steel, Aluminum castings [A356, 356], Aluminum alloy 6000 Series, mechanisms and hardware, plastics – components.

Design new tooling fixtures for Line Staking of Ball Bearings to Retainer [Cage].

Create 3D and 2D models, assemblies and drawing packages.

Write and incorporate Engineering Change Orders [ECO’s].

Develop and issue new part numbers with data using SAP material system.

Interface with customers [OEM’s] such as Boeing, Sikorsky and Bell Helicopter.

Utilized Pro-E Wildfire 2.0, UG NX6, and Solidworks 2009.

AFL Telecommunications ACA Conductor Accessories, Duncan, SC Sep 2006 – Sep 2009

R&D Design Engineer

Responsible for mechanical design/development, process, and testing of new “accessories” [hardware] used in Utility, Power transmission and distribution (Energy sector), 115kV, 230kV or less, 345kV & 500kV products.

Designs were developed from castings [sand cast, permanent mold]; material – A356, 356, H1000 Aluminum.

Design various jigs and fixtures for production.

Design and create 3D Geometry SLA’s for tooling prototypes; Responsible for release and issue 3D CAD design models with drawings through Inventor VAULT and ADEPT configuration database system.

Design fixtures for hardware testing - ATP, QUAL and Low/High Voltage.

Create 3D and 2D library parts for models, layouts; create 3D and 2D models, details, assembly and drawings for manufacturing; utilized parametric, non-parametric, parameters and constraints in 3D solid modeling.

Create Casting, Machining, Welding and Sales Presentation drawing packages.

Create BOMs and routings; Write Engineering Change Orders [ECO’s], Design Change Requests [DCR’s].

Performed FEA Stress Analysis on designs using Inventor Pro – Ansys.

Perform Acceptance and Qualification Tests.

Develop and implement Test Plans, Reports and Installation Instructions.

Implement the principles of LEAN Manufacturing, Kaizan, and 5S philosophies.

Perform Customer PPAP, PFMEA, DFMEA, and Cpk analysis; perform Cost analysis/estimation and cross-reference of Sub-Station, Transmission/Distribution hardware; perform quality checks and process flows.

Develop and issue new part numbers using ORACLE material system.

Interface with customers [OEM’s] such as Metal Castings, Duke Energy, NEETRAC and material vendors [fasteners, hardware, SLA’s].

Utilized Autodesk Inventor Pro 2010, FEA and AutoCAD 2009.

PREVIOUS EXPERIENCE:

TYONEK Corporation (TEAMCOR) Warner Robins, GA Feb 2005 – Aug 2006

Design Engineer III

Electro-mechanical design/development of Electrical packaging & enclosures for aircraft hardware and test sets.

Create PCB Electrical equipment layouts and test equipment.

Create 3D/2D models, details, assembly and customer drawings, as well as 3D/2D drawing packages for prototypes and manufacturing.

Write ECO’s, Process Material and Documentation specifications, Manufacturing Work Instructions, Test Plans and Failure Analysis reports.

Perform Cost estimates – quotes and conceptual layout development.

Evaluate and consider reliability of design failures, welding, corrosion resistance and material issues utilizing aluminum and stainless steel.

Liaison with local and out-of-state manufacturers, suppliers and Government.

Interface with OEM’s on sheet metal fabrication, electrical hardware, Air Force.

Utilized Autodesk Inventor Version 09/11 and AutoCAD 2005.

Champion Aerospace, Inc. (contract Southeast Technical Services) Liberty, SC. Mar 2004 – Jan 2005

Product Engineer

Electro-mechanical design/development of Electrical packaging and enclosures for the F135 Exciter on the main aircraft Engine ignition system.

Designs utilized Stainless Steel 300 series, electronics and adhesives.

Create 3D models, details and assemblies.

Design various fixtures for prototypes, testing and manufacturing; build prototypes for product process development and testing.

Liaison with local and state-side manufacturers, suppliers and prototype makers.

Write ECO’s, Process Material and Documentation Specifications, Manufacturing Work Instructions, Test plans and Failure Analysis reports.

Evaluate and consider reliability of design failures, welding, corrosion resistance and material issues utilizing aluminum and stainless steel.

Utilized Autodesk Inventor, Solidworks and AutoCAD 2005.

Parker Aerospace Dublin, GA Sep 2000 - Jan 2004

Senior Design Engineer Servo Controls Division

Mechanical and Electro-mechanical design of linear, electronic [AC-DC motors, Analog, Digital], hydraulic actuators for missile control [Aft Cowling, Elevon and Aileron] and Flight Control systems; mechanisms and machine components.

Designs consisted of Aluminum [6000-7000 series], motors, ball screws, bearings, gears, fasteners, plastic [injection molded parts] and adhesives. Valves designed from Aluminum [6000-7000 series] and A356, 356.

Served as Mechanical and Sustaining Technical Lead on JAVELIN Antitank Missile System-Control Actuation System; responsibilities for this position included design, development, testing [ATP,UTP,QUAL]

Create 3D and 2D models, details, and assembly drawings for prototypes and manufacturing.

Build prototypes for product, process development and testing.

Write and implement Engineering Change Orders, Test Plans and reports, Failure Analysis reports, and Manufacturing Work Instructions.

Involved in new Electro-Mechanical product design, development proposals.

Create technical illustrations for marketing brochures and other documents.

Liaison with local and overseas manufacturers, suppliers, prototype makers and Government [Army, Air Force, Marines], OEM’s such as Raytheon and Lockheed.

Utilized Catia V5 and AutoCAD 2003.

CAMACO-Lorain Manufacturing, Lorain, OH Jan 1996 – Jul 2000

Product - Tooling Design Engineer

Responsible for design/development of mechanical automotive components, seat frame parts and assemblies – automotive engine hardware - lever arms, mounting brackets, seat adjustment brackets, seating; also designed conveyors, machine components and mechanisms for press.

Designs consisted of sheet metal, plastic [injection molded parts], machine components, tube fabrication, tube bending, sheet metal stamping, and adhesives.

Utilize welding [mig, tig, robotic], performed destructive testing and analysis.

Create tooling, dies [single, blank, progressive], various jigs and fixtures for production.

Design and build test equipment.

Create 3D and 2D models, details, and assembly drawings for prototypes and manufacturing.

Write Engineering Change Orders, Design Change Requests and BOMs.

Perform Cost estimates – quotes and conceptual layout development.

Performed customer PPAP, DFMEA, PFMEA, Cpk functional analysis on products as well as APQP functions.

Performed new tooling “buyoff” analysis, perform PPAP and CPk analysis before release to production floor.

Implement Lean manufacturing and 5S principles on manufacturing and work cells

Liaison with local and state-side vendors, suppliers, prototype makers and OEM’s – GM, Ford, Chrysler, BMW, Toyota, Lear Seating and PL Porter.

Utilized Solidworks and AutoCAD – Achieved Six Sigma Greenbelt Certification.

Bath Iron Works, Bath, ME Oct 1989 – Dec 1996

Senior Liaison Designer – Mechanical/Machinery/Piping

“Cradle to Grave” design, development, and implementation of mechanical, hydraulic, pneumatic, high/low pressure air, steam, fuel and lube oil mechanical/piping shipboard systems on the AEGIS Destroyer program.

Utilized sheet metal for equipment mounts, drip pans and pipe hangers, structural steel for rigid and hard mounts, pipe fabrication, tube fabrication and bending used in shipboard systems. Piping systems 50-1500 psi systems.

Design and develop hydraulic valves from castings [sand cast, permanent mold]; material – A356, 356, and 6000-7000 Series Aluminum.

Calculate flow rates, pressure drops and pipe bends.

Create 3D models, details, assembly drawings and BOMs for manufacture- 3D Library Parts for models.

Write Engineering Change Orders [ECO] and Design Change Requests [DCR].

Liaison with manufacture, engineering, suppliers and OEM’s such as, Government [Navy], General Electric.

Utilized Catia.

Newport News Shipbuilding, Newport News, VA Mar 1980 – Sept 1989 Senior Designer – Mechanical/Machinery

“Cradle to Grave” design, development and implementation of machine components, mechanisms, actuators, hydraulic and pneumatic valve mechanical/piping shipboard systems on the Los Angeles and SEAWOLF class Fast Attack submarine program.

Designed jigs and fixtures for prototypes, test equipment and manufacture.

Design and develop hydraulic valves from castings [sand cast, permanent mold]; material – A356, 356, Aluminum.

Create 3D and 2D models, details, and weldment and assembly drawings for manufacture.

Create 2D layout drawings for prototype development. Perform Stress Calculations.

Liaison with manufacturing, engineering, suppliers and government [US Navy].

Utilize CADAM, AutoCAD and VIVID 3D CAD.

EDUCATION/CERTIFICATIONS:

BS in Mechanical Engineering Technology, Indiana State University, Terre Haute, IN

AAS Mechanical Engineering, Triangle Institute of Technology, Pittsburgh, PA

AAS Specialized Mechanical Technology, Triangle Institute of Technology, Pittsburgh, PA

Six-Sigma Greenbelt 2000 Certification

LEAN Manufacturing – Kaizen Principles – Rapid Improvement Process [RIP]

BS in Business Administration program [18 credits], Southern Wesleyan University, Central, SC

Held Confidential and Secret Clearance(s) – US Citizen

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