Mechanical Engineer Engineering

G h a f o o r K h o d a y a r i, P h D, P . E n g .

** ***** ******* ****; Thornhill, On, Canada Cell: 647-***-**** ; E-mail: *************@*****.*** HIGHLIGHTS

Over 25 years of experience in a wide range of mechanical engineering (North America and Germany),

Expert in developing industrial manufacturing concepts, methods, processes and innovative technologies

(Automotive, Aerospace, Nuclear and Medical),

Design and manufacturing of special vacuum chambers for maintaining medical and surgical objects and components,

Developing special airflow systems for surgical operation rooms isolating the body of patient to minimize the risk of contamination by operation team (for a German Hospital),

Formability/failure, Strain/Stress analysis, Material testing, material specification,

Expert in metal forming processes (stamping, welding, extrusion, roll-forming, injection-molding, bending, cutting, and hydroforming, …),

Design of Experiments (DOE), Prototyping, assembling, process analysis, process control and improvement,

Design engineering (AutoCAD, SolidWorks, GD&T, Blueprint Reading), Automation and Control,

Excellent in understanding and solving of complex technical and engineering problems supported by exceptional analytical skills and attention to details,

Excellent leadership, interpersonal, teamwork, and oral/written communication skills,

Can effectively communicate with Design team, Management, Production personnel, Customers and Suppliers,

Fluent in English and German languages (both reading and writing),

PhD. In General mechanical Engineering (Germany),

P. Eng. licensed (Ontario),

PROFESSIONAL EXPERIENCE

Senior Manufacturing Engineer: April 2015 – Present Employed with a North American Company involved in design developing and manufacturing tubular components for automotive applications using various metal forming processes. Modification Team Lead (OPG, Nuclear); Sept 2014 – Jan 2015

Involved in Design, Manufacturing and installation of reactor emergency cooling water system (pumping station, filtration, control system, and monitoring),

Leading stakeholder’s and design service provider’s meeting,

Providing work plans and reviewing the installation procedures and design and project completion. Senior Project Engineering (Aerospace) April 2012 to July, 2014 Employed with Amphenol Canada Corporation, a North American Company involved in design, R&D, testing and manufacturing of electronic and electro-mechanical components for Aerospace, Military and commercial applications including but not limited to the following activities:

Developing high performance plating (multiple layers),

Environmental tests (vibration, mechanical and thermal shock, salt spray, conductivity etc..),

Design and developing of parts and components and design optimization (using Solidworks),

Design, develop and testing fastener systems for high dynamic applications,

Application of Military, Aerospace and other customer standards. Project Engineer (E.S. Fox Ltd.) April 2009 – Oct 28/2011 BRUCE NUCLEAR POWER PLANT, TIVERTON (Bruce “A” Unit 1 & 2 Restart Project)

Involved in various CANDU-related project engineering activities,

Developing material and part specifications for nuclear applications,

Designing, Modeling, FEA (using AutoCAD, CADkey, SolidWorks), Prototyping, Manufacturing and testing and approval of equipment/devices/fixtures,

Pre Production Qualification (PPQ) for manufacturing and component quality,

Analysis and determination of tubing system clearances and tolerance,

Dimensional measurements using Laser system and approval of component and manufacturing accuracy,

Project cost forecasting, preparing NCRs, RCOs, ITPs, …

Simulation and presentation of manufacturing process (computer based as well as on Muck up). Senior Mechanical Engineer April 2006 - Dec 2008

Vari-Form Inc, Strathroy, Ontario, CANADA

Vari-Form is a Tier 1 and 2 automotive structural components manufacturer company using Hydroforming process. Along with other engineering activities, I have successfully organized, managed and completed various large-scale manufacturing and R&D projects in collaboration with GM, Ford, Chrysler and Honda as major clients. My further engineering activities were in following areas:

Developing industrial manufacturing methods for automotive structural components from advanced high strength steel materials by Hydroforming process (weight reduction),

Formability and failure analysis (FLD, FEA), Strain/Stress analysis, Material testing, material specification,

Production engineering, prototyping, components measurement and validation,

Assembling techniques and processes (design, develop and optimization),

Optimization of manufacturing processes, waste reduction, online part measurement and quality control,

Material testing (Tensile, Impact, Fatigue, Hardiness…) and Micro-structural analysis,

Material and part specifications, CAE, APQP, PPQ (PPAP), PFMEA, R&D,

Root cause effect, troubleshooting, continuous improvement,

Managing R&D projects in areas of metal forming technologies (e.g. bending, hydroforming, stamping, laser welding, etc.),

Generating experimental Forming Limit Diagrams (FLD) applying circle grid analysis (stress/strain analysis),

Frequent technical paper author & conference speaker presenting the company in national/international seminars/conferences,

Member of company’s board of technology & managed the company’s intellectual properties and patents. Project Manager/Metalforming Technologies Feb 2001- March 2006 IRDI (Industrial Research and Development Institute), Midland, Ontario, CANADA At IRDI, I was the principal scientist in providing comprehensive and documented engineering solutions and research studies to North American manufacturing industries including Automotive, Aerospace, Medical, etc; mostly in conjunction with United State Council for Automotive Research “USCAR”, U.S. Automotive Materials Partnership

“USAMP” as well as Auto Steel Partnership “A/SP” to develop lightweight Hydroformed components. The highlights of my activities are as following:

Managing engineering projects (R & D),

Design, Development and manufacturing of automotive structural components (using AutoCAD, CADkey);

Part and die design optimization, Prototyping,

Developing innovative manufacturing methods and processes for industrial applications,

Process design/planning and process optimization,

Metal forming technologies (cutting, stamping, injection molding, bending, Hydroforming, cutting, tribology…),

Formability and failure analysis (FLD, FEA), Strain/Stress analysis, Material testing, material specification,

Developing special components for medical/surgical applications,

Industrial applications of Laser and High Pressure Water Jet,

Feasibility studies and material properties testing (tensile, hardiness, fatigue, durability, impact, crash etc..),

Applying for Government research funds,

NVD (Nickel Vapor Deposition) process to develop special components for medical (surgical) applications, Senior Mechanical Engineer Feb 2000 - Feb 200l

Multimatic Technical Center “MTC”, Markham, Ontario, CANADA MTC is an engineering service provider company specialized in the application of advanced vehicle dynamics simulations, design engineering, prototyping and vehicle systems. I was involved in design and development of automotive parts and components, conducting feasibility and manufacturability studies of designed parts. One of my major contributions has been the design and development of a unique stamping process to manufacture an extruded component from steel plates of 5 mm thickness to replace special door hinge bushings (high saving potentials). Head of Engineering April 1994 - Nov 1999

Department of Mechanical Engineering, University of Siegen/Germany Post-Doctoral activities; leading and managing the Department’s research engineering team and technical staff involved in R&D projects in conjunction with German industries (e.g. Schuler AG, Mercedes Benz, VW, VAW, ..). During this time period: teaching graduate and undergraduate mechanical engineering students in Methods of Manufacturing, metal forming and industrial applications of Laser, Plasma and High Pressure Water-Jet cutting. PUBLICATIONS, AWARDS and PATENTS

Published over 20 technical and scientific papers in national and international technical magazines,

The “FABRICATORS & MANUFACTURERS ASSOCIATION”-Award for 2003 North American best technical article; Published in “TPJ-Tube & pipe Journal’s”, June 2003 issue,

US-Patent “A Method of Forming a Hollow Body with a Hollow Flange” using Hydroforming process EDUCATION and Degrees (in Germany)

I obtained equivalency accreditation in 2009 at the University of Toronto.

PhD in Mechanical Engineering (Investigations on material behavior in elastic and plastic deformation), Germany,

Master’s in Mechanical Engineering (Developing a parametric CAD Program-Module for automated design of industrial components), Germany,

B.S. Metallurgy (Studying micro-structural changes in steel materials due to heat-treatment), Germany. REFERENCES: Available upon request

Contact this candidate