Mechanical Engineer Quality Assurance
Resume:
MICHEL HELOU
Windsor, Ontario N*J *S* · M: 248-***-**** P: 519-***-****
ad5c87@r.postjobfree.com
A dynamic Mechanical Engineer with over 20 years’ design and validation experience working with hardware, electronics and software. I’ve worked on a diverse range of projects within the automotive industry executing significant improvements to products, resulting in cost saving measures and client satisfaction. I’ve demonstrated strong collaboration skills working with different internal teams, and client organisations nationally and internationally.
I value being a life-long learner, which has provided opportunities to work on new technologies within the areas of mechanical and electrical engineering. I have a wide range of interests beyond the automotive industry and seek new challenges that allows my work to provide a positive contribution to society.
SKILLS & KNOWLEDGE
Mechanical and Electrical systems
Analytical chemistry
Neural Network and Fuzzy Logic Controller
Data acquisition software and data analysis
Technical reviews, recommendations and education
Process and product improvements
VAVE/Product life cycles
High Voltage Certificate.
RF Electronics, CAN, CanCase and LIN.
High Voltage SAE Certificate
NVH
Project management
Research and development
Testing, troubleshooting and quality assurance
Collaboration with diverse stakeholders
Native English and Portuguese speaker, high proficiency in Spanish and working knowledge of the German.
DFMEA, GD&T, 8D, DOE, and Teamcenter.
DVP&R
SAP, ASPICE, PLM and Windchill.
Laboratory Experience
TECHNOLOGIES
Mathematica
Maple
MATLAB
Simulink
Mathcad
Prolog.
Linux OS (RedHat, Debian and Slackware)
Linux Kernels
AutoCAD
Eagle
SPC
Minitab
Microsoft Office Suite, Microsoft Visio, Microsoft Project
C/C++, LaTeX, Fortran.
EXPERIENCE
MAR. 2018 – FEB. 2024
SENIOR COMPONENT DEVELOPMENT ENGINEER, HANON SYSTEMS INC.
Successfully designed and constructed a load simulator to use during an EMC test as per company standards.
Worked at the High Voltage Lab for the testing and assembly of the electronic load simulator.
Worked closely with clients to compose a comprehensive EMC test plan of an E-compressor for Ford Motor Company. Including follow ups, reviews and final approval to ensure the plan met the client’s needs.
Worked with external contractors for the construction of an anechoic chamber lab for an EMC test and ensured it met standards and regulations required by law.
Worked with a team to lead the technical review for the detailing of several mechanical drawings for release and approval of compressor manufacturing.
Active participation on the Design Review Meeting for the E-compressor, Battery Pack Testing outline in DOORS software and HVAC system of electric vehicles.
Instructed CAD designers on new concept and/or design modifications of mechanical powertrain components, and reviewing primary sketches and drawings, design approval and release for manufacturing.
Working the supply chain for ordering parts, components and raw materials.
Participate on weekly design/drawing reviews meetings, with vendors and within the department in order to achieve cost reduction with improved quality, and meet customer requirements.
Worked with VAVE department with the focus on reducing costs, improving function and quality, by way of teamwork-based product evaluation and analysis. Participation on weekly quality meeting with customers and 8D resolution to investigate any root cause of failure.
Managed a project that ensured the functioning of a load simulator that used CAN communication protocol.
Reviews of all documentation related to product design, manufacturing, purchasing and testing to ensure that quality requirements are met, and this Includes the review of design drawings, test procedures, data, inspection analyses, and customer specifications.
Provided quality assurance support to assigned programs to ensure the product is designed, procured and manufactured according to customer quality requirements.
Coordinating internal and external test requests for e-compressors and battery pack such as NVH, electrical functional test, leakage test, thermal shock, Battery CAN controller communication.
Utilised a range of enterprise resource planning and CAD software such as SAP, Windchill, DOORS, Redmine and Catia for build, design, product planning and costs.
JAN. 2010 – FEB. 2018
SENIOR APPLICATION ENGINEER, schaeffler group usa
Successfully designed and constructed a load simulator to use during an EMC test as per company standards.
Worked at the High Voltage Lab for the testing and assembly of the electronic load simulator.
Worked closely with clients to compose a comprehensive EMC test plan of an E-compressor for Ford Motor Company. Including follow ups, reviews and final approval to ensure the plan met the client’s needs.
Worked with external contractors for the construction of an anechoic chamber lab for an EMC test and ensured it met standards and regulations required by law.
Worked with a team to lead the technical review for the detailing of several mechanical drawings for release and approval of compressor manufacturing.
Active participation on the Design Review Meeting for the E-compressor, Battery Pack Testing outline in DOORS software and HVAC system of electric vehicles.
Instructed CAD designers on new concept and/or design modifications of mechanical powertrain components, and reviewing primary sketches and drawings, design approval and release for manufacturing.
Working the supply chain for ordering parts, components and raw materials.
Participate on weekly design/drawing reviews meetings, with vendors and within the department in order to achieve cost reduction with improved quality, and meet customer requirements.
Worked with VAVE department with the focus on reducing costs, improving function and quality, by way of teamwork-based product evaluation and analysis. Participation on weekly quality meeting with customers and 8D resolution to investigate any root cause of failure.
Managed a project that ensured the functioning of a load simulator that used CAN communication protocol.
Reviews of all documentation related to product design, manufacturing, purchasing and testing to ensure that quality requirements are met, and this Includes the review of design drawings, test procedures, data, inspection analyses, and customer specifications.
Provided quality assurance support to assigned programs to ensure the product is designed, procured and manufactured according to customer quality requirements.
Coordinating internal and external test requests for e-compressors and battery pack such as NVH, electrical functional test, leakage test, thermal shock, Battery CAN controller communication.
Utilised a range of enterprise resource planning and CAD software such as SAP, Windchill, DOORS, Redmine and Catia for build, design, product planning and costs.
JAN. 2009 – JAN. 2010
SOFTWARE ENGINEER, FORD MOTOR COMPANY (contract)
Managed various software development projects for transmission thermal modelling and stop/start electric motors. Supported all internal clients by providing technical support to run MATLAB and Simulink software, to run simulations of mechanical engine components to optimize fuel economy and improve engine performance.
Developed the software for Battery Management Systems to improve the state of electric charge and health of batteries used in electric vehicles.
Worked with various internal departments to employ control strategies to assess vehicle capability that meets the desired fuel economy and optimum engine performance for all vehicles including hybrid.
Collaborated with the IT team to release and upload different versions of simulation software using ClearCase Rational for internal departments.
JAN. 2005 – DEC. 2008
SYSTEMS DEVELOPMENT ENGINEER, NAVISTAR INTERNATIONAL TRUCKS
Project managed and defined the requirements of systems for a Volkswagen client. Responsible for the execution of new design, analysis of test data, electronic control unit software development and quality assurance plans of various diesel engine components for the Brazilian market.
Worked with Mitsubishi suppliers and plant personnel to implement material changes to eliminate corrosion and deterioration of exhaust gas recirculation (EGR) valves, which led to significant cost reduction in manufacturing and also producing better quality parts.
Worked with the materials lab for analysis of engine cylinder sleeves to address failures in diesel engines during field tests. Data was collected and plotted to identify any discrepancies inside piston cylinder sleeves.
Successfully provided two recommendation actions to the company and supplier of EGR valve housing for material change from cast iron to high grade steel, and manufacturing process change from sand casting to investment/commissioning casting (lost wax casting) to eliminate sulfuric acid corrosion due to high sulphur content on diesel fuel in Brazil (3500 ppm) and with this change the company was able to gain a cost saving of $100 per valve. (Award of Engineering Excellence)
Coordinated with the chemistry lab work for fuel and engine oil analysis using a gas chromatograph, to evaluate the impact on diesel engine components from chemical contamination in fuel produced in Brazil.
Managing and implementing engineering changes and new designs to meet specifications for the successful launch of diesel engines.
Developed software using MATLAB for spectral analysis from field data stored on a data recorder to determine whether resonance was present on thermostatic valves.
Using technical expertise to effectively communicate information between internal and external departments on cost reduction manufacturing and process improvement of engine components.
JAN. 2000 – DEC. 2004
SENIOR MECHANICAL ENGINEER, SIEMENS VDO AUTOMOTIVE
Project management for the design and construction of mechanisms and electrical controllers used to simulate engine roll movement that was completed on time and on budget for validation of intake manifolds and other engine components (CHRYSLER).
Worked on the design and development of new wire harness connector testing equipment (Continuity Test) in conjunction with the supplier to meet customer requirements throttle body of IC engines.
Designed and built an electronic response time test driver which met the criteria to measure response time of actuators and which led to high volume tests for intake manifolds resulting in increased customer satisfaction on the launch for the PACIFICA – Chrysler vehicle, design of DC motor control circuit design.
Applied principles of fluid mechanics in analysing problems with air leakage on GM intake manifolds which led to identification and correction of the problem and decreased production defects
Worked with projects alongside the NVH group to validate mechanical components through analysis of thermodynamics and mechanical vibration principles
Design and development of variable and fixed voltage power supply for many electronic test device equipment, using discrete semiconductor components.
Research and development of the active noise control project for the Jaguar that led to the assembly unit which provided both Jaguar and Honda’s customer a way of actively control engine noise thus increasing engine efficiency (Active Noise Cancellation Project)
Led numerous field tests to gather critical data (e.g., vehicle engine sound signatures) used to update electronic boards design features.
Prepare plans and specification for a commissioning a Vacuum Pulse Generator test equipment, Flow bench test, salt spray test, climatic and environmental test to simulate the engine running condition which helped identify problems with the design requirements and minimized downtime during production.
EDUCATION
2018
MASTER OF SCIENCE, CHEMISTRY - UNIVERSITY OF DETROIT-MERCY, USA
1997
BACHELOR OF MECHANICAL ENGINEERING - UNIVERSITY OF TECHNOLOGY SYDNEY, AU
AWARDS
Second prize winner of the Shell Challenge Award fuel cell project
Award for Engineering Excellence by Peak Technical Services
LANGUAGES
Portuguese, Spanish, and French (intermediate level)
INTERESTS
Passionate about science and research, I embarked on a master’s degree late in my career to learn more about the intersection of chemistry and engineering while also applying it to my work at the time. RF Electronics, Advanced Amateur Radio License by Industry Canada. I also like to work on my Linux OS computer which gives flexibility on modification such as recompiling and using different software programs, such as C/C++, Prolog, and Fortran programming and I enjoy oil painting and swimming in my spare time and reading in areas of science and philosophy.
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