Product Development Design

Marcos Antonio Goncalves

Pindamonhangaba, Sao Paulo, Brazil 12413-170

www.linkedin.com/in/marcosabgoncalves • +55-12-997**-**** • ******.***********@*****.***

Senior Product Designer

Multifaceted technical career with 20-year track record of innovation and success

Technically gifted engineering professional with 15 years of solid experience in aerospace industry and 7 years in automotive (mechanical and electronics parts). Broad knowledge of various engineering design areas such as mechanisms, control surfaces, structures, and product development. Proficient in creating fully functional prototypes by incorporating cutting edge technology and testing them for accuracy. Skilled trainer and project leader; designated as Guardian of Lean Design Methodology in work area for proper implementation of Lean Design techniques. Credited with a US patent for creating innovative device and methods for testing quality of welding joints through Friction Stir Welding.

Technical Proficiencies

Tools:

CATIA V4/V5 (Part Design, Assembly Design, Aerospace Sheet Metal Design, Composites Design, Kinematics, Generative Analysis), Microsoft Office Suite, 3DCOM/DMU, SAP (BOM), AutoCAD R14

Methodologies:

Lean Design, Design to Manufacturing, Design Failure Mode and Effect Analysis (DFMEA), Process Failure Mode and Effect Analysis (PFMEA), Relational Design, Quality Function Development (QFD), Geometric Dimensioning and Tolerancing

Professional Experience

Embraer, Sao Jose dos Campos, Brazil

Product Designer – E175-E2 Wing Fixed Trailing Edge (2015 - 2016)

Technical Scope: CATIA V5R24 (Solids and Surfaces Modeler, Kinematics), 3DCOM/DMU (Parts and Product Structure Creation and Management), SAP (BOM)

Oversaw maintenance of functional characteristics between fixed trailing edge structure and control surfaces such as Ailerons, Flaps, and Spoilers. Provided critical technical interface to engineering teams requiring understanding of stress analysis, safety, and manufacturing. Played integral role in parts and assemblies modeling. Liaised with industrial partners such as Sonaca from Belgium and FACC from Austria in troubleshooting efforts while rendering interface support at all times. Involved in creation of Bill of Materials (BOM) in Production Planning (PP) module of SAP, describing list of parts of components needed to assemble product.

Key Achievements:

Actively spearheaded on Joint Definition Phase and executed the entire phase within timelines.

Embraer, Sao Jose dos Campos, Brazil

Product Designer – KC-390 Military Support (2011 – 2015)

Technical Scope: CATIA V5R24 (Solids and Surfaces Modeler, Kinematics), 3DCOM/DMU (Parts and Product Structure Creation and Management), SAP (BOM)

Led KC-390 military support program within the company, conceptualized design of main door primary structure, and suggested improvements in internal mechanisms of the twin-engine jet-powered military transport aircraft. Interfaced and collaborated with engineering teams involved in stress analysis, cabin safety, manufacturing etc to ensure successful execution of designed product. Partnered with Aerovodochody (Czech Republic) for troubleshooting and resolving technical issues. Engaged in various tasks like parts and assemblies modeling in addition to creating BOM for input into the Production Planning module of SAP.

Key Achievements:

Designed Life Raft access opening mechanism, developed entire structure, and effectively worked on constructing a fully functional proof of concept prototype.

Utilized Lean Design methodology in achieving 20% weight saving, 15% time saving, and 30% production cost saving while designing main door of military transport aircraft KC-390. The first prototype was certified to be fully functional with minor rework.

Enhanced Cargo Handling System and initiated patent process by designing a new Tow Link mechanism and assembling a functional prototype.

Embraer, Sao Jose dos Campos, Brazil

Product Designer – Legacy 450-500, Phenom 100/300, 1st Generation EJets (2001 – 2011)

Technical Scope: CATIA V5R22 (Solids and Surfaces Modeler, Kinematics), 3DCOM/DMU (Parts and Product Structure Creation and Management), SAP (BOM)

Directed all aspects of mechanical assembly development in the manufacturing of Legacy 450-500 executive jets including PAX door structure, Flap Inboard Panel mechanism, and Elevator and Rudder Panels. Performed parts and assemblies modeling to ensure smooth execution of finalized design by the implementation team. Prepared BOM lists for Production Planning module of SAP. Involved in all aspects of Product development for Phenom 100/300 Executive Jets including movable surfaces and flight controls. Oversaw first generation EJets project, co-designed air stairs optional feature, and also completed necessary documentation.

Key Achievements:

Achieved weight saving and production cost saving of 15% on PAX Door System of Legacy 500 Executive Jet by leveraging Lean Design Methodology.

Catalyzed substantial stock cost saving amounting to 50% by implementing entirely new concept of flexible driveline clamps (plastic injection) in Flap system of the jet.

Prior experience includes the role of Aeronautical Designer at Dynamic Solutions from 2000-2001, Designer at Valeo Lightning Systems from 1999-2000, Product Analyst at Magneti Mareli COFAP from 1995-1998, and Technical Assistant at Magneti Mareli COFAP from 1993-1995.

Education and Certifications

Bachelor of Engineering, Production Engineering (Ongoing 2014-2019)

Brazilian Virtual University Institute, Sao Paulo, Brazil

Associate of Science, Metallurgic Processes Technologist, 2011

Faculty of Technology, Sao Paulo, Brazil

Certifications

CATIA V5 Mechanical Design Specialist ~ Dassault Systèmes (C-X99BAYPERN)

CATIA V5 Surface Design Specialist ~ Dassault Systèmes (C-8XQC3L789U)

US Patent Number US20140157862A1

Device and methods for testing quality of welding joints (Friction Stir Welding) ~ 2015

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