Engineer Design

PROFESSIONAL SUMMARY

Aerospace Engineer, Black Belt Certified with 11 Patents and with 27 years of experience in the areas of Project Management, Structural Design, Quality(DOE, PFMEA,SPC, ISO9000), Reverse Engineering, Manufacturing Processes, Mentoring and New Product/Process Introduction. Self-motivated with international experience and good interpersonal skills, bringing out the best from everyone in the team.

Greenville Energy and Research (GEAR)

Chief Engineer 02/2015-11/2015

Leading and coaching an engineering team in the areas of Structural Design, Reverse Engineering and Combustion, consulting Executive team and customers on design issues, presenting program updates and progress to customer, involved in purchasing and refurbishing of Gas Turbine engines and other capital equipment.

Major Responsibilities:

Monitor Design progress through Design Reviews with engineering team

Present to customer solid engineering solutions on Gas Turbine engine modifications

Negotiating and evaluating suppliers for the construction of various engine components

Overseeing tests of refurbished engines and evaluate the results

Training engineers on various structural and Gas Turbine performance engineering topics

Create algorithms for various design calculations that can be used by engineering

Create design guides for future applications

Provide realistic schedules on effort and time required for the execution of various design tasks

UTC Aerospace Systems

NPI Program Manager 06/2014-12/2014

Owner of certain GE projects regarding Industrial Turbines Hot Gas Path parts. Responsible of the Design and Manufacturing of various EDM and CMM tools used in the production processes. Main interface with the customer on issues regarding Design, Schedule, Budget and Process capabilities for various parts.

Provided corrections on computer models (SolidWorks) thus preventing the generation of defective parts

Contributed in the corrections of manufactured EDM fixtures that could become problematic during production

Coordinated with customer Cost Reduction initiatives by minimizing the cycle of special processes steps

GE (1989- 2014)

Senior Requisition Manager, Gas Turbines New Units 2012-2014

Coordinated project’s completion by collaborating across multiple customers, engineering organizations, Manufacturing, Architectural & Engineering firms, Business Associates and installation/field personnel. Provided single point contact for all customer technical inquiries, questions and communications related to assigned equipment projects. Provided technical guidance and financial / schedule impact of customer requested scope changes. Monitored progress of design activities and resolved technical issues.

Worked closely with the customer and coordinated the resolution of over 250 pending issues on drawings, undelivered documents, equipment changes at site and various errors on drawings within 6 months

Led a small team and increased department’s productivity by developing a new tool that reduced search time of customer’s drawings status by 95%.

Senior Design Engineer, Compressor Blades and Vanes 2005-2012

Set design direction and carried out design responsibility for new turbine designs. Monitored design progress of assigned tasks and took timely actions as necessary. Reviewed design concepts and analytical approaches and recommended alternative paths when appropriate. Coordinated the interactions of other functional organizations in the design process to maximize the effectiveness of the design, with respect to cost, producibility, quality and reliability. Ensured that designs conformed to standard practices and design practices and that design records were maintained and monitored in accordance with department procedures.

Carried out the structural design, qualifications, testing and implementation of the “Full Span Hybrid” Inlet Guide Vane (IGV) for the 7FA+e Enhanced units. Introduced and carried out from concept to implementation the non-welded design of the 2 piece IGV. Implemented foolproof features preventing operators’ installation errors. This design has become the customer's choice of IGV configuration for the aftermarket units.

Participated in prototype engine tests and helped field engineers on issues with compressor hardware.

Consulted and mentored domestic and global teams on hardware designs and modifications. Led local and global teams in various RCAs, DFSS and DMAIC projects and provided sound results met cost reduction objectives and helped teams toward on time resolutions.

Participated on components' qualifications and assisted suppliers to improve their processes using Six Sigma and Kaizen techniques in order to achieve and meet drawing requirements thus delivering on time quality parts.

Program Manager New Product Introduction 2001-2005

Led major New Product initiatives in the Energy Services, aimed at developing new gas turbine products/components for current production units that enhanced performance, improved quality and reduced overall product cost. Provided engineering assessments and generated resource requirements for approved programs. Provided program management and technical leadership for approved programs to ensure deliverables meet Product Specification and design-to-cost requirements. Coordinated new product transition from development to production. Coordinated planning and preparation for component and engine test programs. Provided leadership and guidance to less experienced Program Managers

Completed over 20 programs exceeding business goals of reaching over $500M in sales.

Managed and delivered the new three interval 1st and 2nd air-cooled blades of the 7FA and 9FA units, yielding to the business sales and productivity over $200M in two years.

Contributed to the growth of the GE Services into the Reverse Engineering (RE) sector by managing the execution of all Gas Turbine RE programs. Authored the Design Practice of the RE in GE, thus contributing into the projected 36% growth increase of this business from ~$200M in 2004 to $500M in 2007.

Managed sensitive strategic programs providing customer value in the area of ceramic components, Liquid Fuel Reliability, Clearances control and Laser technology.

Black Belt Structural Component Design Engineering 1998 – 2001

Implemented and drove Six Sigma quality breakthrough strategy in Structural Components Design Engineering. Assisted quality leadership to uncover and access global GEPS and supplier Six Sigma opportunities by institutionalizing Six Sigma and Kaizen Quality techniques as the priority and global measurement.

Exceeded the department’s yearly commitments by creating, organizing teams and completing successfully projects by utilizing effectively Six Sigma, Kaizen and DFSS methodologies, by delivering savings to the business over 450% from the yearly targets (1999 and 2000 consequently).

Launched and established the Six Sigma DMAIC Quality initiative in India’s GE branch by teaching courses, coaching, training engineers and establishing the first successful set of projects.

Maintained department’s readiness of ISO9000 high by continuously providing training and being actively involved in “Red Team” and “Work Station” audits. Became certified ISO9000 auditor (RAB-Q09181).

Design Engineer Commercial Modifications and Upgrades 1997-1998

Appointed as the owner of “Flange-to-Flange” activities for modifying field units. Modification included changes or rework on all stationary and rotating components of the units as requested by the customer, limited design on new parts and implementation of new technologies in the field, in order to upgrade old units and improve their performance (Output and Heat Rate).

Contributed to a “record sales” (1998) of Energy Services, over $400M, by successfully responding and completing on time over 300 requisitions from the customers.

Became the key interface between Energy Products, Research and Development and Field in the area of brush seals implementation and testing.

Production & Design Engineer Bearings/Unit Instrumentation 1991 – 1997

Owner of all bearings in factory and field units. Supported Manufacturing, Field Services and Sourcing to resolve technical non-conformance issues associated with flange-to flange hardware, unit assembly, bearing design and performance across all frame sizes. Interfaced with the customers and responded to their technical requirements and concerns. Coordinated vendor qualification activities to successfully meet manufacturing schedules. Introduced new ideas based on Six Sigma methodologies for reducing product cost, improve cycle time and maintain high quality of the product.

Delivered the 9FA+ thrust bearing design, optimized the oil-lift design of the F units’ journal bearings and implemented standard bearing instrumentation for temperature detection across all units in the fleet reducing hardware cost by 80% and simplifying Bill of Materials structure by 90%.

Led the Production Engineering efforts in assembling and testing of over 350 gas turbines.

Led the Manufacturing Review Board (MRB) Assembly and Test team from 1992 to 1997. Organized and directed various Root Cause Analyses on Production and Manufacturing issues.

Introduced the “Offset Alignment Concept” for the “F” size frames, an innovative process that eliminated defect rework by 100% and reduced significantly the cycle time during the unit’s alignment.

ADDITIONAL RELEVANT EXPERIENCE

General Electric Aircraft Engines (Lynn, MASS) – Systems & Performance Engineer 1989-1991

Corry Manufacturing Co. (Corry, PA) – Manufacturing & Flow Design Engineer 1987-1989

The Ohio State University (Columbus, OH) – Teaching and Research Assistant 1983-1987

SKILLS

Patents: 8,033,785, 7,985,053, 7,752,726, 8,196,280, 7,600,977, 6,691,019, 6,408,705,

6,385,834, 6,354,735, 6,352,362, 6,227,061, others pending

Papers: GT2004-54296 “Non – Metallic Brush Seals for Gas Turbine Bearings”, ASME Turbo Expo,

Power for Land Sea and Air, June 2004, Vienna, Austria

RAB ISO9000 Certified: Quality Management Systems Auditor, Cert. Number -Q09181

Computer Skills: MS Office tools (MS Word, Excel, PowerPoint), MINITAB, SolidWorks essentials, UG essentials, ANSYS.

EDUCATION

MS Business - Management of Technology Rensselaer Polytechnic Institute, Troy, NY

MS Aerospace Engineering The Ohio State University, Columbus, OH

BS Aerospace Engineering The Ohio State University, Columbus, OH

BS Naval Architecture & Marine Engineering Center of Higher Tech. Education, Athens, Greece

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