Mechanical Engineer A Senior

James P. Pillar Jr.

Qualifications

Over ** years’ experience in machining, forming, heat-treating, design, and testing of iron, steels, aluminum, and magnesium alloys

Experience with polymers, ceramics, glass ceramics, polymers, hard and soft coatings, and adhesives

Experience with design of both components and complicated assemblies

R&D of manufacturing improvements (ex. hard burnishing of oil seal surface), material development (ex. high hardening low alloy steel) and oil/grease and oil additives

Development of custom/specific testing for various R&D programs

Verification testing, derived from customer requirements through both standard and special testing

Author of Technical and White papers and recorded several invention records

Knowledge of tribology measurement and analysis, ISO 25178 proof reader

Able to read complicated assembly drawing, knowledge of GD&T

Released hundreds of production drawing of both components and assemblies per ASME Y14.3 Education 1988 – 1993 University of Cincinnati Cincinnati, OH B.S. Materials Engineering

Professional Practice Performance Certificate

2004 – 2006 University of Toledo Toledo, OH

M.S. Mechanical Engineering

3.638 GPA

Professional

Experience

2020 – 2021 Science Applications International Corporation (SAIC) Huntsville, AL Sr. Mechanical Engineer – DS.AAMD Air & Missile Defense

Participate in Project planning activities, estimation and schedule development.

Identify and manage hardware requirements with a focus on mechanical, environmental, electromechanical, thermal and material performance.

Work with a multi-disciplinary team to develop primary designs based on functional decomposition of requirements using DAD/CFD/FEA, modeling, simulation, analysis and rapid prototyping.

Perform detailed design and verification activities to take prototype designs to maturity.

Integrate functional components into Line Replaceable Unit (LRU) – level designs. Support integration of LRUs into higher-level systems.

Support acceptance testing of LRU and systems per customer requirements, e.g. MIL-STD-810.

Generate and Review documentation for a Technical Data Package associated with the design, development, unit test, and integration of hardware components.

Assess technical and integration risk and help identify mitigations.

Review test plans and procedures; Review and adjudicate Deficiency Reports.

Review relevant milestone contract deliverables and provide recommendations across the life cycle of a development effort.

2014 – 2018 American Axle & Manufacturing Detroit, MI Sr. Product Engineer – Driveshafts

Plan, initiate and track engineering design projects for passenger car and truck applications

Develop, validate and release driveshaft designs

Coordinate driveshaft design analysis processes

Maintain engineering project budgets and schedules

Coordinate prototype builds for applicable designs, including advance prototype procurement

Provide Bill of Materials (BOM) and technical information to support cost estimates

Present written and technical communication to customer

Provide design recommendations and technical support to application engineers

Coordinate DVP&R testing

Provide technical direction to CAD designers, manufacturing, process engineers, suppliers, purchasing, analysis, and test engineers as well other product engineers Phone: 419-***-****

E-mail: **********@*****.***

Address: Huntsville, AL 35824

2008 – 2014 General Dynamics – Land Systems Sterling Heights, MI Sr. Armor Design Engineer – Materials Engineering and Survivability

Responsible for the Design, Development and Integration of Armor Systems for light to heavily armored tracked and wheeled vehicle programs

Armor upgrades and supplemental armor systems for such programs as FCS, ABRAMS, Stryker, MRAP as well as other yet unnamed experimental platforms for the U.S. Land Warfare Systems

Work closely with both TACOM and ARL to develop and integrate new and add-on Armor Systems to defeat newly identified and continually developing small, medium and large ballistic threats in all theaters of operations

Exercise extensive customer coordination as well as the ability to work within the design standards and common design practices associated with military vehicular design to assure designs and design changes are completed in a timely and effective manner 2006 – 2008 General Dynamics – Land Systems Lima, OH Sr. Materials Engineer – Operational Engineering & Liaison Engineering

Provide Materials Engineering technical support to all programs and manufacturing operations at Joint Systems Manufacturing Center (JSMC)

Support planning, prototype hardware fabrication, and assembly processes for current and new vehicle programs and act on engineering issues that have the potential to interrupt program or delivery schedules

Identify and communicate engineering problems to the proper design authority (TACOM, DOD, Army, Navy, Marines) for joint resolution using problem reports and Engineering Change Requests (ECRs)

Resolve Material Problem Reports pertaining to supplier issues

Create Engineering Change Proposals (ECP's), Deviations and Waivers to resolve technical design and manufacturing issues

Provide technical support & project management on multiple engineering projects

Provide engineering support to production through Material Review Board (MRB) activities

Provide technical interface with on-site customer the U.S. Government Department of Defense 1999 – 2006 Dana Corporation Ottawa Lake, MI

Materials Engineer – Advance Technology Research / Development Group

Identify, research, develop, and recommend new materials and processes to incorporate into current, developing, and potential products and processes

Provide failure analysis, solutions, and recommendations related to engineering materials, process, heat- treatment, and inspection specifications

Provide materials analysis related to manufacturing, product and supplier/customer concerns

Project management from inception, through development and validation of test methodologies through experiment, experience, customer requirement, and team participation

Evaluate and interpret test results and report generation including solutions and recommendations

Investigation and analysis of applied research projects including a Department of Energy Research Grant

Perform both standard and non-standard tests as requested by customers

Work with various disciplines, from quality and production control to advanced engineering throughout the corporation, in a team environment to develop engineering and material solutions

Operation, maintenance, and repair of numerous laboratory and analytical equipment including Scanning Electron Microscopy (SEM), Energy Dispersive Spectrometry (EDS), X-ray Diffraction (XRD), Optical Emission Spectrometry, optical interferometry

Research, identify, and purchase analytical and testing equipment to support present and future needs

1999-2001 Board of Examiners “Dana Quality Leadership Process”

A2LA Accredited Laboratory ISO Guide 17025, Certified Internal Auditor 1993 – 1999 Dana Corporation Syracuse, IN

Metallurgical Engineer – Spicer Light Axle Division

Production control and quality improvement of carburizing, induction hardening, heat treating, welding, machining, and assembly operations in a Tier I automobile and truck (class 5 to 8) supplier production facility

Management of unionized inspection department workforce

Program and operation of a coordinate measuring machine

QS9000 Documentation, APQP, PPAP, FEMA

1991 – 1993 Kaiser Aluminum Newark, OH

Metallurgical Engineer Co-op

Production control and quality improvement of casting, heat-treatment, extrusion, rolling, and drawing of various aluminum and magnesium alloys

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Patents and

Publications

Analysis of Rotary Swaging Tooling Rolling Contact Fatigue and Life Improvement Under Service Conditions – STLE Second World Tribology Congress - Vienna, Austria, April, 2002

Development of the Methodology for 3-D Characterization of Oil Seal Shaft Surfaces – SAE 200*-**-****

Hard Turning as Finishing Alternative for Spline Shafts – IASME CPR-17 #0310 (Internal Conference on Production Research August 2003)

Surface Finish for A Case of Continuous and Interrupted OD Hard Turning – IMEC2003-42538 (ASME IMEC November 2003)

Hard Turning as Finishing Alternative for 1117 Steel Camshafts – International Journal for Manufacturing Science & Technology, US Library of Congress, ISSN 1524-1548, Volume 5 No. 2 2003/2004

Invention record for “Slip Yoke Barrel with Multiple Surface Textures” Dana Case 5768 UJ R&D, patent pending

Invention record for “Interference Burnishing Manufacture of Slip Yoke with no Preferential Lead”, Dana Case 5576 R&D and 5658 R&D, patent pending

Professional

Associations

Society of Tribologists and Lubrication Engineers (STLE)

American Society of Mechanical Engineers (ASME),

Society of Automotive Engineers (SAE)

References Available upon request

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