Engineer Injection Molding

Resume

GREGORY R. ZAMBECK *********@*****.***

W294 N6940 Burbank Court Call 1 to 5 pm M to F - 601-***-**** cell

Hartland, WI 53029 Skype gregz6806

https://www.linkedin.com/in/gregory-zambeck-b383a5b8/

Summary of Skills

Project Management from $1 to $130 Million while supervising 3 to 20 people, over a 27yr. career with Medical, Automotive, Appliance, Aerospace & Construction Industries.

Thorough knowledge of the following Applications, Codes and Guidelines:

AutoCAD/Inventor 2018, SolidWorks Abaqus – CSWA /Cosmos 2016, Pro-E/Creo 4 Direct-Elements & Parametric, Whindchill, Solid Edge, MATLAB 2016, Allen Bradley PLC, WinStable, Ponds, Labtech, Thermovision, COMSOL, ANSYS 17, CATIA V5, Compress, MBD/SCADE, DFMPro.

NDT, AWS, ASME, ANSI, NSF, API, DOT, GD&T, ASCE, AISC, OSHA, NEC, NFPA, FMEA, DFMEA, QFD, SIX SIGMA, ISO 9000, PPAP, SQF, HACCP, GMP, KPI’s (and more)

Professional Experience

OMEGA V Engineering, LLC. Hartland, WI 8/2012 – Present

CFD & FEA Analyst.

Product Design / Manufacturing & Process Engineer w/ Project Management

CFD Analysis of Aeronautical electronic components using Inventor 2018 & Thermal Desktop

CFD & FEA analysis turbine simulations resulting in an 8 to 12% increase in flow. Creo 5 & Catia V5.

Developing High Precision CNC Machining for Medical CT Scanner components, diamond wire saws, robotic assembly, mounting, tooling, fixturing, loading & CNC machining & Inspection of parts 70% reduction in rework, SPC of manufacturing process, FEA Modal analysis of Machining operations, 60% to 110% increase in production, 30% reduction in waste with a 3x to 5x increase position in accuracy.

Solidworks 2018, Inventor 2018 & Creo 5. MS Office MiniTab 18

Design of Pharmaceutical control systems. – Aerotek, Inc. Inventor 2018

CFD Analysis of Fiber Glass Industrial ovens – Oxford Corp. Intl. SolidWorks, Inventor FEA & CFD.

3D printing two filament printer and I'm using FTP, PLA, APLA, ABS, Nylon, TPE - Flexible, PETG, Hips, PVA & Polypropylene with Glass and Carbon fillers.

CFD Analysis of Water Treatment Tank 45% reduction in treatment time – Contract Inventor CFD

High speed automated dispenser redesign -

Electronic connector design –

High Speed food processing and packaging plant Ind. Ovens, AB Controllers, QC & Process control. –SQF, HACCP, GMP, KPI’s Inventor 2016.

Storage container design – Plastic Injection molded – Multi-cavity CATIA V5.

Hydraulic pump design – Current contract – Plastic Injection molded - Single-cavity

FEA analysis of construction Equipment – Maxon Ind. - Abaqus SolidWorks FEA.

Root Cause analysis of product failures – Contract

Residential Foundation failure analysis and testimony. - Contract SolidWorks FEA.

Suspension design to reduce component weights using Aluminum / Cast Iron assembly 50%. - Contract SolidWorks FEA, FLOW-3D.

Design & Implementation of 16 new products as Project leader with Manufacturing, Production, - Purchasing, Quality Control capturing 20% of the market in the 2nd. Year of $ 3.6 m CEA.

Process improvements using plasma spray application of Cathodic protection.

Developed Hydro-formed 7024 / 3004 Aluminum cladded material for lightweight tanks.

Developed new extrusion, Hydro-formed process for 22% increase in heat transfer

FEA & CFD analysis of Heating, Combustion, Refrigeration & Air Conditioning systems.

Design & review of all technical drawings, specifications & quotes. CREO w/ PLM & SolidWorks– GD&T DFMEA

30% improvement in efficiency, with a 20% increase in capacity, 17% improvement in orifice flow.

Developed modulated combustion burner w/ 15% increase in rate, Low Nox Electrostatic burner

Computer Controlled Point of Source Electric Water Heater with computerized testing for lifetime cycle testing. – Vacuum Forming, Single cavity injection molding

AS 400 - product data management.

Structural analysis of building frames, & Monument relocation – SolidWorks FEA

Oxford International Granville, OH 5/2017 – 3/2018

CFD & FEA Analyst.

Working cross functionally with Construction Services, Energy Management, Furnace Engineering, CFD Simulation Services, and Concrete Reinforcement Division. MS Office

CFD analysis of global industrial glass process ovens – Autodesk, Inventor 2018, PDM, SharePoint, Fusion, using ANSYS, AGM & Solid Works Simulation software 2018.

Cost savings of $15 mil to $ 84 million dollars, 75% reduction in energy requirements.

Eliminated $380,000 heat exchanger cost by specifying proper high temp filtration systems.

Reducing heating cost for South Korea, India, France, Italy, Brazil and Russian oven systems involving heat recover, burners (Air/gas & Oxy/gas), foundations, dryers, melters, steam heat, building structures.

Light Weight, Hollow Core, FRP floor slab design to reduce construction time by 30%.

HHO automotive applications obtaining 20% to 30% fuel cost reductions, emission w/ 60% reduction in maintenance.

Oxford Corp. Madison, WI 2/2012 – 8/2012

Product Engineer - Contract

Design & CAE of thermal fluid heaters for industrial engine systems.

Simulated testing of engine cooling systems with AB PLC control systems. MS Office

Design & Implementation of sub-zero to hi-limit life cycle testing. - CREO & SolidWorks Solid Edge– GD&T

Thermal analysis of heating, impact, stresses testing of injection molded plastic DEF tank components.

Design of injected molded components & tooling for thermal heaters, ultrasonic level and density sensors

Single cavity injection molding – Insert Molding

(End of contract)

OMEGA V Engineering Cedar Hill, TX 11/2010 – 2/2012

Owner Consultant

Design Scotch Marine Industrial boilers from 40 to 900 bhp. with blowdown separators, feed water systems and thermal fluid heaters.

Produced & reviewed shop drawings. - Inventor MS Office

Implementation of Q.C. corrective actions

Reduce design flaws,

Improve quality control

Reduce production errors

Commercial Burner controls & Specifications

(Accepted new position)

Dover Corporation. Jackson, MS 1/2009 – 11/2010

Product Design / Manufacturing & Process Engineer w/ Project Management

Specialized design of gas and electric commercial cooking equipment while reducing cost and developing innovative solutions to current and new production units. MS Office

Developed new 4 and 6 pan, gas and electric steamers from prototype to production units in 4 months.

Develop new 45-gal, gas & electric kettles and all technical drawings; use CFD to increase efficiency from 78 to 86%. – Pro-E, Windchill & SolidWorks– GD&T DFMEA

Reduced fabrication cost with new fixture designs with FUNAC robotic welding and bending stations.

Made use of SAP to Set-up steamer and kettle assembly lines for lean manufacturing and regulatory compliance

Designed new condensate drain, reduce water usage from 400 gallons/day to 10.

Use FEA in the structural, vibration analysis. Single cavity injection molding

Computerized product life cycle testing - AB PLC control systems

MAPICS – product data management.

(Laid off with 50% work force reduction)

OMEGA V Engineering Tyler, TX 2/2006 – 1/2009

Owner Consultant

Design & Sales of Natural gas self-cleaning mist coalescing, filters, scrubbers, separators and odorizers and valves for commercial pipe lines, resulting in an 8% cost reduction for clients. CREO & SolidWorks

Project Management and FEA design and analysis of commercial and residential foundations, mono-pole, tri-pole and guyed pole tower foundations, retention walls, pavement design, foundation failures, mining explorations and construction inspection requiring supervision of 6-man crews.

Design & analysis of soils exploration drilling equipment, reconditioning and maintenance, threaded connections, tip designs, materials, fabrication drawings & specifications. AutoCAD MS Office

Autoclave Design & medical certification to ANSI 1414 / 2192 / 2182 - Strelis

Central Testing Laboratory, Inc. Leesburg, FL. 2/2003 – 9/2006

Staff Engineer

Responsible for Geotechnical, Environmental, and Materials Engineering.

20% reduction in report cost by field use of computer access. MS Office

Project Management of remedial measures for structures affected by sinkholes, foundation design, site development, drainage, construction inspection, as well as mining, land filling, environmental, hydrologic and geologic studies or evaluations with drawings & specifications. AutoCAD – MicroStation – GD&T

(Reduction in viable construction projects, started private business opportunity)

Westcast, Inc. Westfield, MA 10/1998 – 11/2002

Product Design / Manufacturing & Process Engineer w/ Project Management

Developed new down firing Low NOx residential boilers, 75K to 210K with automatic monitoring hardware and

software, also low NOx, 20Mbtu/hr commercial boilers.

Increase efficiency of 5 Mbtu/hour Oil Boilers

Directly interfaced with service & maintenance to increase boiler reliability - AB PLC control systems.

Designed, specified while completing 420 drawings in setting up boiler assembly lines for lean manufacturing. AutoCAD & Pro-E – GD&T MS Office

Balanced Nat. gas regulator design - Single cavity injection molding

Patentable non-resonant plaque burner

(Left to help aging and infirmed mother in Florida)

American Water Heater Group Johnson City, TN 6/1997 – 10/1998

Product Design / Manufacturing & Process Engineer w/ Project Management

Engineer in charge of gas product line redesign.

Realized a 12%-part reduction

12 to 18 % savings in manufacturing and material cost for lean manufacturing

Developed low cost NOx burner for 30 to 65K applications. - AutoCAD & Pro-E – GD&T MS Office

(Laid off with 40% work force reduction after losing the Home Depot business and closing the Reno plant)

Lincoln Brass Works, Inc. Carryville, TN 7/1996 – 6/1997

Product & Applications Engineer

Project Engineer for patented sealed burners with flame retention & re-ignition for 5K to 15K ranges.

Designed/developed open top range burner for hot lighting making an 800,000 order

Developed Low NOx burners for water heaters, infrared space heaters & brooding applications

Development of capital investment specifications all progressive burner tooling & lean manufacturing

Design progressive dies & Material transfer systems and all drawings. – AutoCAD – GD&T MS Office

(Left for position at AWHG)

Harper-Wyman Company Aurora, IL 8/1992 – 6/1996

Product Design / Manufacturing & Process Engineer w/ Project Management

Product engineer responsible for directly interfacing with sales and production to meet customer’s requirements for new and enhanced design within the Sealed Burners/Re-ignition Group.

Created new diecast & sintered aluminum processes and material in development of new sealed burners, in applications to domestic and international markets with sales of 2 mil/ yr. completing all technical drawings.

Developed patented Modulating Thermostat for production on existing valve assembly line to compete in the international market with sales of 4 mil/yr.

Life cycle testing of low friction coatings to increase product life by a factor of 5x. - Pro-E & AutoCAD– GD&T - AB PLC control systems MS Office

Developed injection molded auxiliary switch which resulted in increased sales from $2,000 to $250,000 annually, with a 32% cost reduction with sale of 500,000 annually.

Collaborated with manufacturing in setting up Six Sigma program and SAP for real time monitoring.

Design of injected molded tooling for high speed ignition switch and wire assemblies of 1.5 mil/yr.

(Laid off with 12% work force reduction)

IVON Corporation Canton, MI 10/1990 – 8/1992

Chassis and Suspension Engineer

Tasked to decrease component fatigue & weight reduction 8% to 30%.

Use of FEA to increase chassis rigidity 12% to 34%

Increase handling through proper selection of suspension components with Hypnue Software

Increase engine performance 12% to 20%

LP & CNG conversion for gas and diesel engines for mobile and stationary systems - AutoCAD MS Office

(Contract Position) Left for position at H-W.

Oven Builders, Inc Farmington Hills, MI. 8/1989 – 10/1990

Product Design / Manufacturing & Process Engineer w/ Project Management

Developed bi-directional, gas fired, double wide conveyor oven by encompassing high tech materials.

Use of CFD to re-vectored gas flow and heat distribution resulting in eliminating thermal failures, decreased balance recovery by 400%, increasing combustion efficiency 40%, with a 12% increase in heat transfer - AutoCAD– GD&T AB PLC control systems MS Office

Redesign of oven and burner components which improved ignition response, flame recognition and ignition component failures completing 540 technical drawings.

Computerized data acquisition and infrared software to reduced testing cost by 70% -

Design of LN fast freeze pizza conveyor.

(Contract Position – Project completed)

Testing Engineers & Consultants, Inc. Troy, MI 3/1984 – 8/1989

Staff Engineer

Head of Roofing Department managing projects from 1 to 130 million – 2 yrs.

Computerized product testing involving servo motors, valves, pumps, actuators for simulation of environmental conditions.

Initiated use of AutoCAD system for 60% reduction in drafting time

Reduced infrared cost by 300% by implementing preventative maintenance programs for NFPA

Prepared plans and specifications for the design and quality control of pavement resurfacing and reconstruction, press foundations, precast bridge, construction, & roofing systems FM

Conducted infrared surveys, vibration monitoring & analysis, structural & foundation failure analysis, destructive & non-destructive product testing - AutoCAD MS Office

(Recruited by and accepted position with Oven Builders, Inc.)

Education

Bachelor of Science: Civil Engineering - Detroit Institute of Technology – 1981

http://www.ltu.edu/registrars_office/academic_records_dit.index.asp - Records at Lawrence Technological University

E.I.T. Michigan

Instructor for Civil and Mechanical Engineering labs at DIT

Mechanical Engineering classes at Wayne State University

PROJECTS

Sinkholes US 19 – Groveland, US 441 - Ocala, US 301 - Cita, US 44 – Wildwood, Leesburg HS, CR 468 - Adamsville, Crarrington Res. US 27 - Leesburg

Combustion - Smith Boilers, Hydrotherm, Inkster Incinerator Plant, Selective Group Homes,

Bradford-White Water Heaters, Stevens Plating, New Jassmen Bakery, East Lebanon Bakery, Little Caesar's Conveyor, Oven, GM Paint Oven, Amana Gas Range, Roberts Corp. Shrink Wrap Oven. Non-resonant Plaque Burner.

Drainage City of Coleman, Clifford Automotive -

Highway SH-130 Seguin, TX, SR-200, SR-466, SW 60 Ave. – Ocala, CR 464 – Ocala, US 441

Wildwood, SR 222 – Gainesville, Detroit's People Mover, Detroit's Third Street bridge,

Stephenson highway, Pontiac vocational center, Pickney city streets, Novi city streets.

Environmental Critton Hospital, Gibraltar Marina, Hammon Storage Facility, Dow Chemical Midland Tank Farm.

Thermograph Detroit city airport, Detroit science center, UPS - paint facility, Universal Mall,

Selfridge Air National Guard Base, Kirco management buildings, G.E. - plastic

center, Detroit water treatment plant, Alma high school.

Vibration G.M.C. Cordax foundation, Opdyke Stamping 500 ton press

foundations, Pleasant Ridge residential foundations.

C.A.E Oven Builders Inc. - Oven Performance, St. Regis Hotel - caisson foundations,

Pontiac Vocational Center - parking reconstruction, UPS - paint facility.

Foundations St. James Church – Bushnell, Detroit's people mover, National Steel # 2 caster plant,

MichCon - training center, Comerica Bank - computer center, Detroit's, third street bridge,

Pulte Homes - Novi subdivision

Floor Systems Mazda test track, G.M.C. - parts distribution warehouse, Meijer's Store # 63,

U of M - replacement hospital, General Dynamic's - robotic storage, Burroughs

high bay robotic storage, G.M.C. - head light alignment stations.

Product U of M - psychiatric ward window abuse test, St. John's - window head impact test,

Demerol - oven panel load test, Western - expansion joint foam environmental test.

Seismic Toyota, Hayasi, Mori, Freeport Homes, Hawaii Preparatory Academy.

Plant Surveys Chrysler - Sterling Heights Plant, G.M. Flint Truck & Bus, G.M. Tech Center,

G.M. - Highland Park.

Patentable Products & Accomplishments

Low Nox electrostatic burner – patentable/Omega V. Eng.

Modulated combustion burner – 20 % increase in btu./hr. capacity – patentable/ Omega V. Eng.

Low Resistance turbulator – 25 % increase in heat transfer – patentable/ Omega V. Eng.

High Flow Orifice – 17% over Standard units – patentable/ Omega V. Eng.

Draft induction combustion system – patentable/Dover

Condensate Drain Valve - patentable/Dover

Low NOx water heater burner. – patentable/AWH

Residential boiler plaque burners. – patentable/Mestek

Open top range burner for hot lighting. – Patent/Frigidaire

Twist-Loc top burner . – Patent / GRZ /LBW

Thin walled Aluminum Two & One piece Re-Ignition Range Burners– patentable/LBW

Modulating Thermostat for Valve Assembly Line– patentable/HW

Conveyer oven dynamic balance & heat distribution system. – patentable/-OBI /Little Caesar

Gas burner - variable swirl & ignition system. – patentable/-OBI /Little Caesar

H-Pile batter, plumb & axial rotation gauge. – patentable/TEC

Consolidation machine - 4 positions, 16 ton/sq.ft.

Maze solving robot - frame & drive train

460 hp, fuel injected, turbo charged Pinto engine

2 hp double expansion steam engine - machined

Deep water video inspection system - 500 ft.

References: Furnished upon request

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