Engineer Engineering
Resume:
William I. Hughes
Bloomingdale, Illinois 60108
E-mail: acz57k@r.postjobfree.com
SUMMARY
I have 35 years of Engineering work experience, with minimal management experience.
My Engineering experience is concentrated in / General Engineering / Hardware Engineering / EMC EMI Engineering / Software Engineering / Windows, PLC and Micro Controller programming / Manufacturing Engineering / Field Engineering / Advanced Microsoft Office and Visio User / Technician Educator
PROFESSIONAL EXPERIENCE
Life Fitness, Franklin Park, Illinois 2010-2017
Electrical Engineer II
Educated Field Technicians on what information to include on LFTechSupport field issue reporting forms. This resulted in issue resolution in 48 hours.
Cooperated with Design Engineering and Document Control to produce new product Operation, Parts, and Service Manuals.
Developed PDF and video Service Bulletins to record solutions to field issues.
Correct released Part, Service, and Operation Manuals.
Complete Part Number Attributes that were originally entered incorrectly.
Solve field issues by evaluating phone call data, LFTechSupport database entry's and returned PCBs.
Taught Independent Field and re-certify Life Fitness Field Technicians in new technology and review existing troubleshooting principles.
Musco Lighting, St. Charles, Illinois 2009-2010
Engineer Service Coordinator
Assembled a C# program to break down data retrieved monthly from any light farm. The manual process of breaking down the data took 40 hours. Using the program, took 15 minutes.
Compiled a C# program that used longitude and latitude as inputs that calculated the time of sunrise and sunset.
Create new part numbers and part specification for data files.
Modified recorded macros and wrote new Word and Excel macros to automate repetitive tasks.
Using Auto Cad 2000 to make changes to production drawings.
Used the free GIMP Image Editing program to improve the DPI of downloaded component specifications.
Validate ECO changes to guarantee proper field solutions.
Omron Automotive Electronics, St. Charles, Illinois 2007-2009
Test Engineer
Compiled a Visual Basic 6 program to control a flash programmer. Using the programmer to recover over a $1,000,000.00 worth of non-conforming products by reprogramming them with the current software version.
Implemented a functional test fixture to find PCBs not compatible with reprogramming. This eliminates an expensive, unreliable and time-consuming video inspection station.
Championed a production failure analysis program. That processed failed PCBs within 72 hours to a fix or scrap resolution.
Composed quality work guide sheets, improving production processes maintaining ISO 9000 compliance.
Compiled a C# program that reports the frequency of specific PCB failures from automatic test equipment files.
Introduced a program to reduce the Standing Acoustical Wave (SAW) filter reject rate to less than 1%. The testing resulted in meeting the corporate scrap rate objective and no out of box failures.
Used AutoCAD 3D Inventor to design a fixture to hold an air ionizer to blow on an assembly process resulting in a reduction in line rejects.
Used AutoCAD 3D Inventor to design of a Pogo Pin fixture to hold the unit under test. This eliminated a time-consuming two-week rotation of scheduled maintenance.
Coded an Omron Programmable Logic Controller (PLC) to automate a manual test. Resulting in more accurate test results and an increased PCB throughput.
Improved hardware design of a final assembly test incorporating visual and audible test pass indicators. This met a customer requirement.
Compiled a Microchip Machine Code program to add the motor stall function to the offline tester. Resulting in complete testing of the electric window controller.
CEF Industries, Addison, Illinois 2006-2007
Test Engineer
Improved the design of a functional PCB tester resulting in completely functioning PCBs released into the stock room. Also, generated step by step instructions to complete the calibration.
Implemented changes to an electronic test setup for brushless DC motors making it easy to gather and report the test results.
Maintained Air Force test equipment by performing a mandatory device calibrating by using voltmeters, oscilloscopes and load cells. Instituted changes in the calibration instruction including undocumented information.
Created an Excel spreadsheet with macros to calculate the test result percent error of calibration data vs designed data. This resulted in a quick and easy to use no math mistake proof calculation.
Welch Allyn, Buffalo Grove, Illinois 2006-2006
Sustaining Engineer
Performed engineering functions as required to sustain design integrity and continuous production
Replace parts going obsolete used in the production of defibrillators maintaining component specifications. Gaining continuous product production and FDA certification.
Design tests to qualify new parts then wrote reports detailing the procedure for verification of the parts.
Analyzed defective circuit boards to find the root cause of the failure resulting in corrective actions to eliminate their recurrence.
Addressed Battery Discharged Test Equipment issue causing false battery failure. I solved this issue by corrected the calibration documentation and modified the Battery Discharge tester.
Using a spectrum analyzer and sniffer to explored the source of EMC/EMI noise that kept the product from passing noise tests. Resulting in the product passing.
Compiled a Microchip Micro Controller program to provide a 12.000-second clock used in the Battery Discharge Tester. Resulting in a more accurate measurement of total battery discharge time.
Culligan International, North Brook Illinois 1999-2006
Sr. Project Engineer
Working manager of the Electronics Department;
Conceptualized new water softener features including them in Software Specification documents.
Supervise the design of Software and PCB, manufacturing and testing
Executed software and hardware tests on new and existing PCB controllers. Resulting in an $80,000 annual cost savings.
Testing new designs to pass EMC/EMI tests and earning the CE mark and UL approval for European and Domestic market sales.
Participated in a cross-functional redesign team that saved $30,000 per week by replacing a mechanical timer assembly with an electronic timer circuit board, wiring harness and a new molded plastic enclosure. The changes allowed an increase in production from 18 to 35 units per hour.
Compiled a C source code to change the equation parameters for calculating the brine rinse time resulting in test agency approval for the water softener.
Manipulated C source code to incorporate a 1-1/2” flow meter and adding English and Metric selections to the menu, resulting in a new product using existing PCB hardware.
Analyzed field returned and production PCBs to the component level determining the root cause of the failures. Generating corrective action documents preventing issue re-occurrence in production.
Write Field Documentation to inform the field technicians of solutions and changes.
Developed the control box for a Filtered Water Dispenser. The opening of big box store caused a truncated design time. Used off the shelf components to deliver the Water Dispenser. This was an expensive solution but it met the deadline for the store grand opening.
Saving $150.00 per the above filtered water dispenser by specify the use of a gate array to replace expensive off the shelf components.
Software Proficiency
Microsoft Office Programs; Lab View Training; Visual Studio 2005 C#; Visual Basic 6; Auto Cad 2000; Auto Cad 3D Inventor; GNU C and C++; PLC Programming
Education
B.S., Electrical Engineering Technology from Northern Illinois University at DeKalb, Illinois
Outside Interests
Windows Programming C, C++, and C#; Micro Controller Programming, PC Networking; Web Site Design and Cars
Web Sites: http://www.linkedin.com/in/BillHughes1 and http://sites.google.com/site/hughesbill1
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