Reliability Staff Engineer

Daniel Osorno

**** ******** **** ** *****: 678-***-****

Atlanta, GA 30339 ************@*******.***

OBJECTIVE

To pursue a managerial position in the mechanical reliability/quality engineering fields to apply all of my knowledge, education, and project

experience into the successful completion of program goals.

EDUCATION

Graduate

• Georgia Institute of Technology: 08/03 – 08/05 Overall GPA: 3.6 / 4.0

M.S. Mechanical Engineering w/ Thesis

• Cornell University: 01/09 – 05/11 Overall GPA: 4.0 / 4.0

M.S. Systems Engineering

• University of Georgia: 01/13 – 08/14 Overall GPA: 4.0 / 4.0

MBA

Undergraduate

• Georgia Institute of Technology: 01/00 – 08/03 Overall GPA: 3.3 / 4.0

B.S. Mechanical Engineering Graduated with Honors

Certificates

• Six Sigma Black Belt 12/2009

Cornell University

• Red X® Apprentice 07/2012

• Red X® Journeyman 06/2013

Shainin LLC

• Automotive Chassis Technician Specialist (ASG1) 12/2012

• Automotive Electrical/Electronic Systems (AE41) 05/2012

Athens Technical College

• Manufacturing Education Program Certificate (MEP) 08/2005

Georgia Institute of Technology

WORK EXPERIENCE

07/13 – Current

Colonial Pipeline Company

Reliability Staff Engineer (Alpharetta, GA 07/13-Current)

Lead responsibility for the reliability program at Colonial Pipeline Company.

Developed reliability strategy for the company from the ground up including 1-5-10 year reliability framework plans.

Lead responsibility for rotating equipment design, testing, diagnosis, utilization, and repair.

Managed Corrective, Preventive, and Predictive Maintenance program initiatives for all equipment classes.

Functional owner of MAXIMO CMMS system used for asset management, preventive maintenance, and failure reporting.

Provided mechanical engineer support for all districts (pumps, hydraulic systems, heat exchangers, valves, sensors, controls).

Sought budget and resources for execution projects to expand and improve the Predictive and Preventive Maintenance tools and

processes utilized (Vibration, IR, oil analysis, condition monitoring, etc).

Performed failure trend analysis utilizing MAXIMO Asset Management System.

Performed Criticality assessments, equipment sparing strategies, and benchmarking events.

Led the implementation of IPF (Instrument Protective Function) analyses and condition monitoring to optimize equipment and system

maintenance strategies.

Worked on an assortment of mechanical/electromechanical projects to improve pipeline reliability and reduce dependence in obsolete

equipment (HPU, PLC Control Cabinets, Pulsation Dampeners, Relief valve strategies, valve actuation, etc.).

Responsible for Company’s Equipment Maintenance Manual and procedures.

Improved operator checklists and formalized procedures to ensure companywide consistency and compliance.

Responsible for Incident Analysis Root Cause Analysis and Corrective Action to eliminate systematic failures.

Active involvement in recruitment and mentorship of new mechanical engineers.

08/05 – 07/13

Carrier Corporation (United Technologies Corporation)

Reliability Staff Engineer, Corrective Action Team (Athens, GA 11/11-07/13)

Worked in the Truck & Trailer manufacturing facility for North American Operations

Implemented software changes to alleviate customer concerns with premium unit’s performance

Developed and executed qualification plans for new truck engine bearings and suction gas vibabsorbers

Completed Design For Fire Prevention initiatives to increase product safety

Headed Value Stream Mapping event to improve process flow and output. Executed Kaizen bursts to streamline CAT process

Utilized Warranty Life Cycle (WLC) Charts to diagnose product trouble and monitor improvement progress

Performed vibration and balancing benchmarking to reduce product failures

Integrated the use of Six Sigma tools such as Design of Experiments, Statistical Process Control, Analysis of Variance, Gage

repeatability and reproducibility.

Manager – Engineering, New Product Development (Syracuse, NY 08/10-11/11)

Worked in the Global Lead R&D Center for Carrier Corporation

Worked in the development of the NextGen Hybrid Trailer Refrigeration unit (NGT) for EMEA

Worked in the development of the Intelligent Damper System (IDS) product offering for North America.

Led a group of 2 engineers, 1 designer, and 2 technicians in the development of a unit which generated sales to key accounts and

outperformed the competition while maintaining nominal capacity as the previous legacy model that used an unreliable clutch system.

Over 10,000 units (~ $170Million) have been shipped using the IDS system.

Performed concept cost/risk analysis in support of target cost initiatives.

Developed and executed qualification test plans for IDS and NGT product offering.

Developed power, fuel consumption, pulldown, AC/DC, TCO, and system models for NGT product.

Performed engineering qualification (reliability and performance validation) testing for NGT product.

Senior Reliability Engineer (Syracuse, NY 08/07-08/10)

Worked in the development of a new Hybrid Trailer Refrigeration unit for North America (VECTOR 5100/6500/6600)

Focal reliability engineer for entire engineering department.

Developed and maintained Quality Performance Customer Critical-to-Quality (CTQ) metrics to ensure successful product launch

against committed warranty and life speciation.

Maintained appropriate project and milestone documentation such as test plans, test status reports, Failure Reporting Analysis and

Corrective Action System (FRACAS) and drove Design Failure Mode and Effects Analysis (DFMEA) meetings.

Developed and executed qualification plans for VECTOR product offering.

Built process and design FMEA for trailer platforms (VECTOR, IDS, NGT).

Performed qualification testing and system re-design to achieve project reliability goals. Tests included:

System performance and life test

Software regression testing

Extreme Environmental testing

Thermal/Humidity cycling

Ultraviolet (UV) testing

Material mechanical properties (tensile, elongation, fatigue, impact)

Chemical and Flammability Resistance

Highly Accelerated Life Testing (HALT) and Stress Screen (HASS)

Corrosion testing & Salt fog

Algorithm development and optimization

Utilized RCA tools to diagnose failure modes (Fishbone, 5whys, DIVE, RedX, DoE).

Utilized Fault Tree Analysis and Risk projections for system development and benchmarking.

Materialized field data to determine operational conditions of equipment and to diagnose problems.

Utilized statistical analysis to develop compressor operating envelopes, generator temperature/current contour plots, Total

Cost of Ownership (TCO) operating mode calculations, fuel consumption maps, engine loading calculations,

Oversaw Aero-Acoustics and Vibration (AAV) testing (nodal/tonal analysis, airflow testing, vibration sweeps, dwells, natural

frequency response, life endurance testing) .

Updated and maintained reliability reporting tools such as Marciano charts, Duane plots, Pareto charts, reliability growth charts,

Weibull analysis plots, Warranty Life Cycle (WLC) charts, Elephant charts.

Conceptualized, built, and tested the generator HALT chamber based on Arrhenius time-temperature relationship for accelerated

testing including:

Test chamber

Mechanical unidrive

Salt spray, filter, and recirculation system

VFD control

Automatic DAQ and safety shutdown controls

Performed root cause analysis and corrective action of failed components and implemented new reliability FRACAS and QCPC

databases.

Qualified and validated supplier testing for the Edison Generator program. Tests included:

System performance (capacity rating point, High/Low ambient, Demag testing, rotor torque retention).

Thermal/Humidity cycling

Salt Fog testing

HALT/HASS

Current leak chemical detection

Vibration endurance (2M cycles)

Engineering Leadership Program (Syracuse, NY 08/05-08/07)

Transicold Bus Engineering – Product Engineer

Worked in the Global Lead R&D center in the development AvantAC All Electric and Classic platforms.

Created HALT salt fog turbulent air testing chamber for testing AC generators.

Developed FRACAS database and tracking system to record failures and reduce reoccurrences.

Initiated and developed VFD qualification protocols.

CMU MASC (Modeling Analysis Simulation and Computation) – Modeling Engineer

Performed experimental validation of airside FLUENT models.

Performed experimental validation tests for fans, gas heat, and indoor sections of rooftop units.

Developed model to predict fan performance (airflow and shaft power) in accordance with fan laws.

IAQ KCG (Indoor Air Quality Key Competency Group) – Product Engineer

Performed investigatory background and system optimization for novel technologies and IAQ process development.

Performed technology assessments for ERV, HRV, Biocide, UV-C and Ozone technologies.

Created technology insertion matrices for various IAQ technologies.

Georgia Institute of Technology/ Manufacturing Research Center – Atlanta, GA 09/02 – 08/05

Master Thesis: Rolling Element Skew Measurement in a Spherical Roller Bearing Utilizing a CPD Probe.

Undergraduate Research Assistant: Process Optimization for Machining of Hardened Steels.

Hussmann Corp (Ingersoll Rand) – Atlanta, GA 05/00 – 12/01

LEADERSHIP ACTIVITIES AND AWARDS

• Chair of Standard Work Committee for Transicold

Created new standard work documents to enhance testing capabilities and history.

Upgraded standard work documents to reflect new testing procedures.

• ACE pilot for Truck/Trailer division (2009-2012)

Achieved departmental Silver level in 2011.

Achieved ACE Associate certification in 2010.

Owner of Qualification Testing Process (one of five key competencies for CTD SYR).

Championed Value Stream Mapping (VSM) events to reduce package traffic in laboratory and streamline CAT process.

Advisor for the Testing Procedure, and Genset Sustaining Value Stream Mapping events.

• Chair of Employee Satisfaction Survey Committee for ATH Product Engineering. Received most improved award companywide.

• Manager/Owner of Global FRACAS tool and database.

• Manager/Owner of Quality Clinic and Process Charts corrective action tool.

• Founding member of the Intel/Cornell Robotics Cup.

OTHER SKILLS

Reliability: Design for Six Sigma (ANOVA, Gage R&R, Regression analysis, Control charts, CTQ analysis, Pareto/Histograms, SIPOC,

Tagushi DOE, etc)

Design for Reliability (Physics of failure, FMEA, Fault tree analysis, RCA, HALT, Reliability growth analysis, Weibull

Analysis, FEA/CFD analysis, statistical interference, PM & PdM, Risk analysis, etc)

Software: Statistical Analysis: JMP, Minitab, Reliasoft Weibull ++

CAD/CAE: Pro-E, AutoCAD, Mechanical Desktop

FEA: ANSYS, FEMLAB, ProMechanica

Modeling: Matlab, Simulink, Vissim, ESS, Modelica, IPM, Java, Maple

Data Acquisition: LabVIEW, LabPRO, HP Benchlink Datalogger

Office: Access, Excel, PowerPoint, Word, Project, Visio, Publisher

Web development: HTML

Other: Baan, PLC WindLGC microcontroller programming

Languages: Spanish & English (Fluent), French (2 College Semesters) & study abroad program in France

Experience: Lean Manufacturing, RedX, ProCert Training, Fundamentals of Vapor Compression, CNC Machining, Touch typist

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