Engineer Design

STEVEN WHALEY

Yates City, IL ***** 309-***-****

******.******@*******.*** www.linkedin.com/in/steven-whaley-688a2571

Engineering Technician

Analytical, high-performance design engineering leader with 25+ years of experience in motor design, manufacture, testing, and cost analysis for Fortune 500 operations and large corporations. Repeated success launching programs on time and on budget, securing significant cost reductions and meeting customers’ requirements and expectations. A deep understanding of DFMEA/PFMEA, continuous improvement, and change management. Able to clearly communicate appropriate information to colleagues, customers, suppliers, managers, and executives.

Motor Design For Automotive and Construction-(BLDC, Brush, PMDC, Series for Pump)

New Product Development Project Management DFMEA/PFMEA

Team Leadership Requirements Development Testing

Continuous Improvement Change Management Cost Reductions

Quality Management Safety Compliance Communications

CAREER NARRATIVE

CATERPILLAR INC., Peoria, IL 2007 to 2016

SENIOR ENGINEERING DESIGN SPECIALIST (2015 to 2016)

DESIGN ENGINEER (2007 to 2015)

Served as the electric motor expert and designed AC and DC, brush and brushless with integrated PCB, for motors used in the fan, blower, control, and pump machine applications. Interacted with customers, suppliers, purchasing, and product support team. Managed multiple projects simultaneously facilitating original component request through production release.

Applied Six Sigma methodologies as project team lead and subject matter expert (SME) on New Product Introduction (NPI) and Continuous Product Improvement (CPI) programs.

Project Lead Engineer on axial fan underhood cooling for Motorgrader, BLDC force feedback motors for Electric/ Hydraulic steering on Wheel loader, and a large secondary steer motor for electric mining trucks.

Served as Project Lead engineer on both a high profile NPI project while handling a CPI on a Motor Grader that was Decatur’s #1 failure in 2016

Hands-on execution of Advanced Product Quality Planning (APQP), NPI management, Design Failure Mode and Effect Analysis (DFMEA)/Product Failure Mode and Effect Analysis (PFMEA) and Low-Cost Production (LCP) tools and methodologies.

Responsible for writing and maintaining test produces for motors using ISO standards

Led systematic approach to component selection and design by authoring component requirements, test specifications, application guides, and detailed failure analysis procedures.

Championed safety by monitoring office and labs and reporting safety incidents and observations. A member of the component safety team since 2007.

AXIS INC., Peoria, IL 2001 to 2007

COMPONENT APPLICATIONS ENGINEER at Caterpillar

Stepped in under contract to Caterpillar Inc. to assist with engineering assignments for the CAT electronics business unit (BU). Developed specified level and linear, pressure, temperature senders/sensors for machine applications and accessory motors for HVAC and pump applications used in off-highway equipment. Directed several projects from initial request to production release.

Collaborated with customers, suppliers, purchasing, and quality departments.

Tagged as Six Sigma designate team member for NPI and CPI quality programs.

AXIS INC. continued

Directed the component selection and design by authoring application guides, expanding test procedures, and detailed failure analysis procedures.

Emerson Appliance Controls, Indianapolis, IN 2000 to 2001

PRODUCT ENGINEER

Led the product design and provided maintenance support for existing product controls that used PM and synchronous electric motors for this $5M division of Emerson Electric.

Acted as engineering interface with internal safety engineer for all UL/CSA and IEC submissions.

Researched and developed new motor designs utilizing ProE with emphasis on magnet selection, lamination design, and UL approved insulation systems for stepper and timer motor development.

Designed motor cost drivers for preparing and submitting quotes to customers.

EARLY CAREER

ASSOCIATE ELECTRICAL ENGINEER – Bissell, Grand Rapids, MI

PRODUCT ENGINEER – Northland Electric Company, Watertown, NY

TEST ENGINEER, SENIOR LAB TECHNICIAN, LAB TECHNICIAN – Electrolux Home Products, Bloomington, IL & El Paso, TX

EDUCATION & TRAINING

Associate of Science, Electronic Engineering Technology, Hamilton Technical College, Davenport, IA

APQP Training, Caterpillar

Certified Six Sigma Green Belt

IS/IS NOT, Caterpillar

Special Characteristics, Caterpillar

FMEA, Caterpillar

Principles of Acoustics, Bruel & Kjaer

Principles of Vibration Measurement and Analysis, Bruel & Kjaer

Spectral Analysis in Sound and Vibration, Bruel & Kjaer

Sound Quality, Bruel & Kjaer

Universal Motor Course, Small Motor Manufacturer Association, SMMA

Software Tool Capabilities

YES - Yeadon Energy Systems (Motor Design for BLDC, universal, PMDC, shaded pole, and induction motors) 2 years Yeadon was one of the first motor design systems in the 1990s.

Emetor (Online electric motor design software with automated FEA solver) 6 months

Pulse (VBA based spectrum analyzer system by Bruel & Kjær used worldwide. It can be coupled with other software systems (Labview, MATLAB) 2 years

CANalyzer (Comprehensive software tool with intuitive operation for analysis and stimulation of bus communication. I used this tool for one year on analysis and design of PWM controlled BLDC motors)

I'm familiar with programs like MotorCad and MotorSolve from internet trial usage. I worked with a previous engineering manager on a motor design software program (1996-1998) and performed magnetic flux testing to generate the data used in that design program.

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