Engineer Mechanical Engineering

Brian Malek

425-***-**** acy4yn@r.postjobfree.com / acy4yn@r.postjobfree.com www.linkedin.com/in/brian-malek AEROSPACE ENGINEER

Specializing in Aerospace Product Assemblies and System Integration Experienced Mechanical Engineer seeking employment in a professional fast paced team oriented environment. Wherein able to utilize my project management experience in conjunction with my skills such as product validation, process streamlining, and development of new interfaces from conception to delivery.

Detail oriented engineer with experience designing interior component assemblies on commercial aircraft and developing schedule driven custom premium first class architecture.

Proficiency in PDM, Catia including solid modeling and component assemblies V5/Enovia, IVT, SCD, REDARS, engineering drawing approval and assembly requirements. Microsoft Office Project Management Certified.

Experienced in Takt time analysis, Six Sigma, 3D printing, A3 root cause analysis, TRIZ problem solving. EXPERTISE

Commercial aircraft interiors interfaces

New customer work statement authoring

Test plan writing and execution

Customer corrective action resolution

Knowledge of 737/757/767/777 interiors

Analysis of manufacturing for cost and weight

Work compliance with FAA/EASA and Boeing part

requirements.

Project and process streamlining

Solid model design & interfaces

Production support & troubleshooting

New customer feasibility analysis

Supply chain coordination

Design and ordering of new feature tooling

EDUCATION & CREDENTIALS

Saginaw Valley State University (Saginaw, MI)

Bachelor of Science in Mechanical Engineering Program - Graduated May, 2003 Michigan Technological University (Houghton, MI)

Mechanical Engineering Major

PROFESSIONAL EXPERIENCE

Boeing Commercial Aerospace (Everett, WA)

Payload/Structures Design Engineer June 2006 - Present Cross-functional engineering teams designing aircraft component assemblies which must integrate seamlessly to exceed customer expectations, meet strict deadlines and remain under budget on 737/767/777 models. Contributions:

Worked with production team to identify cost savings, production shortcomings and provide new engineering to older designs. Design improvements to detail parts and product assemblies assuring corporate and regulating body requirements are met.

Uses Catia V5 to improve existing interiors, create custom products and define interfaces with associated commodities. Assembled BOM’s, production drawings and interface coord sheets. Coord sheets define commodity layout as well as kinematic operational zone.

Initiates product definition with the customer’s expectation, tooling surface definition, full 3D model, tooling order, assembly build and detail interface. Lead prototype/mock-up builds for first article validation.

Lead checking engineer for contracted work statements, digital part creation, assembly integration, and production build. Verify drawings meet corporate standards in conjunction with GD&T . Production rework was reduced by %90 over the last 2 years.

Streamlines product build cycle for design and production using lean methods.

Initiated digital weight and CG analysis templates for prototype validation. This reduces digital lead time by

%15 and stress analysis by %20

Project teams include foreign designers, Tech drafters, product planners, external suppliers, management and shop mechanics.

Analysis of mechanical quick release brackets, operational range and reliability. Our team re-designed an outboard ceiling latch that eliminated a seal often written up for appearance issues. Packaging Resources (Coleman, MI)

Technical Designer Dec 2001 – Jan 2006

Solid modeler providing plans to tooling machinists and build mechanics Contributions:

Modeled 3D components of thermoforming tooling to build high production assemblies. The engineering team was responsible for a constrained design that could run with a single operator, fit within shop press, use shop air, vacuum and hot water, and be maintained by a single light duty mechanic.

Performed stress analysis on tooling assemblies.

Created 3D solid models used in rapid prototyping, test tools and production tools

Specialized in modular pneumatic high volume tooling. Our team designed and maintained all pneumatic cylinders.

Authored test plans and prototypes of sonic welding jigs William A Kibbe and Associates (Saginaw, MI)

Technical Drafter Nov 1997 – Feb 2001

Architectural drafter responsible for producing drawings used by contract tradesmen. Contributions:

Worked independently to produce HVAC duct system plans

Drafted 2D architectural build and demolition plans

On-site support of fabrication work

Adapted work practices into documented processes

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