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Staff Research Engineer

Location:
Southfield, MI, 48076
Posted:
September 11, 2016

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Original resume on Jobvertise

Resume:

ALOYSIUS U. ANAGONYE RESUME; US Citizen

***** ******* ******

Southfield, MI 48076

248-***-****; acwj5h@r.postjobfree.com

SUMMARY OF SKILLS RELATED TO THE JOB POSITION

I have 7 years of renewable energy system design and development, and over 20 years

experience as an Automotive Research Engineer in manufacturing systems simulation

and analysis, vehicle crashworthiness and occupant safety analysis, automobile CAE

analysis.

7 years experience in renewable energy system design and development with thorough

understanding of solar PV, renewable heating, inverters, racking and monitoring equipment and

excellent knowledge of:

o Research studies in hybrid and electric vehicle design and manufacturing

o Participated in March 2008 US Department of Commerce Sub Sahara Africa Trade Mission

o Developed several projects using renewable energy/efficiency concepts and practices (7 years)

o Developed and several publications and interfaced with various editorial teams for the technical

development and publications - Tracking and ordering mandatory replacement parts during

publications development and for customer verifications

o Has excellent analytical and troubleshooting skills, excellent consulting skills and strategic

thinking, and excellent rapport with colleagues and customers

10 years experience on Crashworthiness and Occupant Protection/Safety using

LS-DYNA3D, PAMCRASH and MADYMO for several new vehicle FMVSS

requirement improvements including:

Subject matter expert in vehicle safety analysis with technical publications,

o

and peer reviewer of technical and safety content of several technical

publications

o Strong understanding of the relevant Laws and Regulations. Experience working

with effective NHTSA compliance programs

o Full vehicle 208 and 214 (Occupant Crash and Side Impact Protections) based

on NCAP and IIHS specifications.

o Finite element modeling and analysis of dummies, vehicles & components

including composites

o Excellent knowledge of vehicle structures, occupant protection and restraint.

o Extensive experience with vehicle crash and sled testing.

o Managed and supervised a team of engineers and technicians in implementing a

low-cost semi-empirical method for estimating the effective vent and leak areas

of an airbag for use in finite element airbag simulation (a GM ROI I had initiated

and developed).

5 years CAE with design for manufacturability analysis experience on Ford and

GM advanced vehicle parts. Lead and supervision of a team in process improvement and

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coordination efforts with the organization global CAE. The designs include total or section

redesigns, thickness changes, ribbings and reinforcement of weak areas of engine

heads, transmission casings and oil pans. The aim is to obtain design improvement

and cost effective structural integrity. Analyses include static, thermal and vibration

using MSC-NASTRAN, IDEAS, ANSYS and ABAQUS with the excellent experience

in:

o Structural FEA analysis including analysis of exhaust systems, engine

components, the design and manufacture of automotive lighting products, impact

analysis and mold-flow analysis.

o Vehicle chassis static and dynamic analyses

o Modal analysis and testing in particular automotive exhaust systems .

5 years experience in plant throughput/bottleneck simulation (Witness, ARENA,

Simul8) and analytical manufacturing system analysis plus m anufacturing cost

modelingin

6 years in industrial engineering material flow research analysis and application

and machining costing, lean manufacturing and manufacturing system line design

and optimization. Plant material flow optimization and minimization of aisle

congestion using AutoCAD Factory Flow and A utoMod. Initiated, created and

developed Plant Performance Analysis in Real Time (PPART) (a GM ROI) .

o Worked with a team at GM R&D on the project - Predictive Modeling of Machining Line Variation

(Patent US 200******** A1) using FEA for machine station error prediction and Weibull analysis

of the station level errors to statistically predict feature quality. A multistage machining process

includes a plurality of stations. The method for predicting feature quality in workpieces is

determining workpiece feature errors. This comprises of decomposing each machining station

into generic machining process steps and determining workpiece errors at each generic

machining process step based on the sources of variation uniquely related to the respective

generic machining process step. Variations in workpiece feature errors influence part reliability

o Managed and supervised a team of engineers and technicians at Orion Assembly plant in its

implementation providing reliability and logistics support for new vehicle lunch by performing

reliability engineering and statistical data analysis activities using Failure Modes, Effects,

Criticality Analysis (FMECA) approach

Managed and supervised a team of software programmers in developing a

o

code for optimal line design (OPTLine). OPTLine integrates line balancing,

machine selection and buffer sizing with throughput and WIP.

EDUCATION

Doctor of Engineering, University of Detroit Mercy

MS Mech. Eng., Northeastern University, Boston

B.Sc. (Hon.) Mech. Eng., University of Lagos, Nigeria

COMPUTER SKILLS

HYPERMESH, PATRAN, I-DEAS, ANSA and LS-INGRID finite element

modeling

MSC-NASTRAN, IDEAS, ANSYS, ABAQUS, LS-DYNA3D and PAM-CRASH

FEA solvers

ANSYS FLUENT (heat Transfer Analysis); FEMFAT fatigue durability analysis

MADYMO lumped mass occupant system modeling and solver code

Simul8, Witness, ARENA and GPSS discrete event simulation codes

MRPS TURNsim, FACEsim, and DRILLsim metal removal simulation codes

CATIA, AutoCAD (Intermediate Level), AutoCAD Factory Flow and AutoMod

Design systems using MATLAB for Modeling, simulation, and prototyping.

Visual Basic, MS Project and proficient with Microsoft Office Suite especially

Microsoft Excel

EXPERIENCE

Green Energy Solution Technologies (GEST), LLC: Jun 2007 Present

o Engineering Manager - Green Energy Solution Technologies (GEST), LLC . GEST is a renewable

energy system design and development company. Extensive experience in renewable energy

(solar and wind) technology program design and development and research studies in hybrid and

electric vehicle design and manufacturing

Developed several projects using renewable energy/efficiency concepts and practices (7 years)

Led diverse engineering and architectural teams on several project design and budget

development proposals Conducted several marketing and financial analyses

Has excellent knowledge of:

o The National Electric Code, Electrical design theory and concepts

o PV design experience with CAD software, Residential and commercial construction

o Quotations and design of residential and commercial Solar PV projects

Developed proposals on:

1. 2# Department of Defense (DoD) Small Business Innovation Research (SBIR) renewable

energy and high efficiency water purification projects.

2. 39.4KW, 11.4KW and 10KW PV Array systems and others.

GM EXPERIENCE: 1989 2007

Research in Material Handling: Nov 2006 May 2007

Research in material handling. Developing analytic models for indirect labor driver

optimization.

Rotational Assignment at Orion Assembly plant: March 2005 Oct 2006

Initiated, developed and implemented Plant Performance Analysis in Real Time

(PPART) a GM ROI and the following activities:

o Participation on new product launch and early warning teams.

o Accumulation and development of data to establish process data labor values

o Used MATLAB to calculate the performance predictions.

o Design the system using MATLAB for Modeling, simulation, and prototyping.

o Involved in Application development, including Graphical User Interface

building using MATLAB.

o Assistance and technical support to the plant in all areas related to quality.

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o Analysis and follow-up on other plant and supplier quality problems as

appropriate.

Research and Development: Jan 1989 Feb 2005

Research in occupant safety and vehicle crashworthiness.

o Developed a code for optimal line design (OPTLine). OPTLine integrates

line balancing, machine selection and buffer sizing with throughput and WIP

o Developed widely used in DYNA3D a low-cost semi-empirical method for

estimating the effective vent and leak areas of an airbag a GM ROI.

Designed and built airbag porosity measurement equipment. See A Semi-

Empirical Method for Estimating the Effective Leak and Vent Areas of

Airbag in the book Crashworthiness, Occupant Protection and

Biomechanics in Transportation Systems, 1999 ;

http://www.angusrobertson.com.au/books/crashworthiness-occupant-protection-and-

biomechanics-in-transportation-systems---1999/p/978**********#

Implemented in LS-DYNA3D; https://www.dynamore.de/de/download/manuals/ls-dyna/ls-

dyna-971-manual-vol-ii-material-models.

o Developed an empirical method for assessing the effect of distance, airbag

folding and airbag packaging on the punch-out and membrane forces of a

driver side airbag.

o Created Finite Element Human Body Model using experiment validation

method. Developed validated Hybrid II dummy neck finite element model.

o Created occupant system parametric finite element modeling and

assembly using LS-INGRID (a generalized 3-D FEA mesh generator for

modeling nonlinear systems).

o Strong understanding of the relevant Laws and Regulations. Experience

working with effective NHTSA compliance programs - Conducted several

analytic vehicle crash simulations on complete vehicle models using LS-

DYNA, PAMCRASH and MADYMO to improve occupant safety and vehicle

crashworthiness for FMVSS requirements .

201 and 202 - Occupant protection in interior impact and head restraints.

208 and 214 - Occupant Crash and side impact protections including

NHTSA & NCAP.

212, 216 and 219 - Windshield mounting, roof crush and windshield zone

intrusions.

Research in manufacturing system simulation and bottleneck analysis, design

and quality, and lean manufacturing.

o Developed a code for optimal line design (OPTLine). OPTLine integrates

line balancing, machine selection and buffer sizing with throughput and WIP

o Plant throughput/bottleneck simulation (Witness, ARENA, Simul8) and

analytical manufacturing system analysis plus m anufacturing cost modeling

and machining costing

Research in machining and metal forming. Developed the following:

o A generalized method for determining the peak and average temperature rise on an insert

that accounts for insert included angle, nose radius, chamfer length and doc

(http://manufacturingscience.asmedigitalcollection.asme.org/article.aspx?articleid=1443971 )

using in house code and ANSYS.

o A method for estimating the dynamic boundary condition for accurate prediction of turning

process part quality using vibration testing and FEA.

o A Predictive Modeling of Machining Line Variation (Patent US 200******** A1) with GM

R&D team using FEA for machine station error prediction and Weibull analysis of the station

level errors to statistically predict feature quality.

ENTECH, Troy: April 1983 Dec 1988

CAE engineer - Ford and GM automobile component analysis including:

Lead and supervision of a team in process improvement and coordination efforts with the

organization global CAE. Design for manufacturability analysis on Ford and GM

advanced vehicle parts - space frames, lighting products, vehicle chassis, Body-

in-white and body components

Analyses include fracture and fatigue life, and static, vibration, transient dynamic,

heat transfer, boundary and material nonlinear using MSC-NASTRAN, IDEAS,

ABAQUS, ANSYS and ANSYS FLUENT

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