Engineer Design
Resume:
PROFESSIONAL PROFILE
Sr. Project Engineer with expertise in electronic systems design and development, and waste reduction. Consistently meets internal and external requirements within time frames and utilizes broad knowledge base to solve problems while meeting all cost, schedule and technical requirements of the program. Planned, organized, controlled and resolve problems arising with assigned projects from initial definition to final stages of production and provide program life cycle support. Effective team player that works collaboratively with all stakeholders to achieve measurable and significant results. Leverage past experiences and successfully completed engineering work in more than one of the following: technology development, product design and development, testing of materials, preparation of specifications, process study, in the areas of System/Design/Manufacturing/Production/Quality Assurance, research investigation and report preparation.
TECHNICAL COMPETENCIES
Sensors- EOIR, FLIR, Sonar, Dual Band Radar, Detectors, Transducers Planning,
Monitoring,
Tracking RF /PWB Products Metrics
DFM/ DFA/DFSS Spec Mgmt Fixtures/Tooling Compliance
Earned Value Mgmt Basis Of Estimates Negotiating Requirement Analysis
Technical Data Package Trade Studies Early Engagement ANSI Geometric Y14.5 Tolerance Studies
SOFTWARE SKILLS
DOORS Rational Rose Solidworks UML Modeling
PRO E Wildfire 5.0/ Creo Element AutoCad Intralink Microsoft Office
MARTIN INTERNATIONAL- PRODUCT ENGINEERING CONSULTANT 2011- Present
• Provide expertise in System Architecture, Requirements Management, Analysis, and Design, Contracts and Proposals in the Medical and Semiconductor industries.
• Provide the engineering view of the user’s version for what the system needs to be and do.
• Mechanical Design/Manufacturing/Product Assurance - while reducing costs, improving efficiencies and effectiveness and increasing productivity.
• Lead efforts in creating and developing fixtures and building test stations for characterization, experimenting and testing of instruments, mechanisms and device/systems.
• Leverage understanding of first engineering principles, advanced engineering methods, data and judgment to influence the course of product development activities.
• Act in coordination and in a liaison capacity with engineering and manufacturing personnel, vendors or customers as required by management.
• Facilitate team interactions and meetings, driving team members to make critical judgments and decisions on projects, and communicating information and status to management as well as to the project team.
• Worked with customer requirements and project goals and assemble and lead cross-functional teams to achieve project goals with respect to functionality, budget, safety, quality and schedule.
• Apply state of the art methods to the creation of new and existing mechanical designs for electronic products.
• Lead major projects (or phases of projects) to resolve advanced and complex technical problems
• Perform Risk Analysis including, Fault Tree Analysis (FTA), Operator Misuse Analysis (OMA), and Failure Mode and Effects Analysis (FMEA) activities to ensure process shortcomings are identified and appropriately addressed.
• Support Risk Management activities to ensure design and process shortcomings are identified and appropriately addressed.
• Debug new designs and develop reliability improvements to existing & new design
• Provide technical support for product engineering, design development, integration, test, and evaluation.
• Investigate the feasibility of new projects, systems, or approaches.
• Work with Quality Assurance and Research and Development to maintain an approved internal Quality System that meets the requirements of GMP’s, QSR, and ISO 9001
• Support complex automated and semi-automated assembly and test equipment.
RAYTHEON COMPANY IDS – SR. PROGRAM/PROJECT ENGINEER 1986 - 2011
Sr. Mechanical System/Design/Manufacturing Engineer
Planned, organized, maintained, originated design and processes while meeting schedule & budgets for the technical, commercial/military data package (documentation) which consists of design concepts (Pro E Wildfire 5.0/Creo Element/Auto Cad/Solidworks solid modeling) & electronic documentation of electro mechanical enclosures /assemblies/products, instruments, devices, mechanisms and sensors-(transducers/radar/combat) systems while meeting manufacturing capabilities, system, industry, regulatory and safety requirements and providing solutions to complex problems. Determined proper technical approach to solve the design requirements. Detailed solid modeling of the concepts to enable rapid learning on the technical challenges. Established early phase selection criteria, prototypes and tests to rapidly converge on a working design. Review existing designs to identify and implement cost, quality, and productivity improvements through advanced approaches. All work resulted in the development of new or refined technologies, products, materials, processes, equipment, and/or scientific method to broaden the company’s Intellectual Property in key strategic areas.
• Generated concepts, design new product mechanisms, sub-assemblies, and packaging; performed rigorous and in-depth engineering analysis; generated detailed design and drawings. Verify and validate documentation IAW ASME Y14.100 (Engineering Drawing Practices), ASME Y14.24 (Drawing Types) and ASME Y14.5 (Dimensioning and Tolerancing.) familiar with, and able to check developmental level documentation IAW MIL-DTL-31000.
• Assessed the feasibility and soundness of alternative engineering processes, products, or equipment.
• From previous machinist experience developed strong knowledge of machining, stamping, sheet metal and fabrication processes for metals and the commonly used plastics.
• Completed a minimum of 2 product life cycles (from concept to production) as a key contributor.
• Lead design for manufacturing (DFM) reviews to ensure producibility, inspectability, testability, maintainability and reparability of New Products and manufacturing processes.
• Provided problem solving in a mechanical design or a production environment together with being a liaison between R & D, Manufacturing & Global Supply Chain.
• Selected appropriate materials (plastics, metals ceramics and composites) and availability.
• Determined customer objectives/requirements and appropriate design solutions.
• Prepared for, and participated in, internal or customer product design reviews.
• Provided engineering expertise/project management for resolution of technical/quality issues affecting products utilizing existing company integrated product design specifications and supply chain.
• Identified and selected vendors, outsource parts and assemblies (off the shelf components, custom items, and fabricated parts).
• Designed and evaluated alternative components/technologies/suppliers for reduced cost or improved quality and reliability, and verifying/validating/implementing changes.
• Ensure design controls are followed throughout the product/process development cycle.
• Planned, scheduled, and coordinated various stages of the Engineering projects to meet delivery timeline within a cross function matrix organization.
• Utilized Document management Systems for storage, retrieval, revision control and approval of Engineering Documentation.
• Prepare engineering specifications and product standards.
• Provide technical guidance to other Engineering personnel.
• Provided leadership and inputs to new vendors, suppliers, processes, and technologies.
• Managed/supported cross-divisional New Product Introductions (NPI) projects and ongoing production.
• Designed mechanical parts assemblies systems and fixtures as part of developing new products and assemblies using modeling tools.
• Conducted mechanical tolerance studies and generated concepts and designs, and implement these designs through procurement, fabrication, installation, and commissioning.
• Fabricate (machined, molded cast and sheet metal components, materials selection and packaging), assemble and test various mechanical products to verify/validate performance to design criteria.
• Investigated and resolved internal and external product issues by designing fixtures, circuit card assemblies, flex cables and modified existing designs to meet new external requirements.
• Assisted project managers in product and advance development.
• Provided the necessary “hands-on” expertise to resolve complex, cross-functional issues regarding product functionality, assembly methods and product qualification while meeting aggressive product cost targets and schedules.
• Defined and supervised engineering tests to qualify designs.
• Mentor, directed/oversee the work of engineers and technicians and worked closely with R&D and Operations personnel.
• Provided system level support to production and field service. Trained and/or provided work direction to technicians and less experienced engineers.
• Constantly engaged with current manufacturing methods, costs, capabilities, and limitations for the practical, effective and low costs design of products.
• Lead engineering teams to the successful completion of project goals. Analyzed and implement continuous improvements to systems for improvements in quality, reliability and cost reduction. Saved $2M through designing a gasket for non-environmental connectors- Awarded a Company Patent after qualification. Eliminated rework and redesign.
• Conducted engineering studies on design for products, associated and subsystems components, and structures.
• Analyzed engineering proposals, process requirements, and related technical data pertaining to design.
• Designed and tested tools and fixtures for manufacturing and quality • Interpreted and evaluated customer prints, requirements, and specifications.
• Developed, evaluated, and improved manufacturing methods, utilizing knowledge of product design, materials and parts, fabrication processes, tooling and production equipment capabilities, and assembly methods. Developed and coached others on engineering documentation.
• Optimized processes and equipment utilization. Monitored and improved product quality and productivity (OEE).
• Develops and designs internal prints and documents • Assists customers with design concepts that optimize effectiveness of customer application Process Engineering.
• Led, designed & developed and field tested Airborne Mine Detection Electronic System for the Gulf War using IR Technology.
• Responsibilities included full leadership and management accountability regarding the performance on all aspects of safety, quality, schedule, and cost performance for the multi-cell/multi-shift operation. In addition, was responsible for setting the standard and driving operational excellence throughout the organization.
• Provided daily interaction with other cross-business teams to maintain and meet organizational goals and objectives. These groups include: technical support, manufacturing/test/design engineering, maintenance, production control, finance and the program management office.
Achieved/exceeded safety, quality, delivery, cost goals and identifying and implementing continuous improvement opportunities using six sigma and lean methodologies.
• Experienced with Supplier/Customer interaction, FRACAS, FRB, Root Cause Analysis, etc. methodologies.
• Responsible for program support activity ensuring flow-down of customer requirements internally and to supplier base. Ensured controls/processes are established to assure products are compliant, as outlined in the Quality manuals, contract/SOW and related technical documents. Interfaced with all departments to resolve Quality/design/production issues in a timely manner by determining root cause, devising corrective/preventive action, closing out related documentation and reporting results to management. All my work required ongoing interface with Program Management Office engineering, manufacturing, suppliers and customers. Also, involved domestic travel to perform audits/source inspections and customer interaction.
• Drove resolution and documentation of non-conforming material and investigation and closing out of Corrective/Preventive Actions using accumulated knowledge of Geometric Dimensioning and dimensional inspection and electro mechanical assembly, including soldering.
• Conducted FAIT- First article inspections to meet the technical requirements of the product.
Worked on the following mega projects:
• THAAD (Theatre High Altitude Defense System) Mechanical/System Requirements Engineer – Concurrent Test, Training & Operations (CTTO) Support Unit
Generated the Design Build Spec, all allocations and completed the decomposition of the Prime Item Development Spec (PIDS) to the Technical Specification for the CSU Outfitted Trailer from the customer.
Mapped the major components, generated all the requirements and verification methods pertaining to the performance, design, and development and test requirements for the Concurrent Support Unit (CSU) Outfitted Trailer, which resulted in a successful Product Design Review (PDR) and a follow on $110 million production contract.
• Patriot System/Mechanical Requirements Engineer
Identify, analyze mechanical assembly tolerance issues and produced solutions for multiple electronic and electro –mechanical products. It was accomplished by originating a plan, measuring data, engaging with the program multi-discipline team, reviewing vendor specifications and providing an interface/tolerance analysis for the multiple electronic designs.
Managed and negotiated the final deliverables by resolving the manufacturing issues by introducing design modifications and process changes to improve efficiencies of current designs and processes while maintaining cost effective ways of complying with current constraints.
• IPASS (Integrated Parts & Supplier Sourcing) - Corporate Program
As an SME, directed and coordinated the Mechanical Technical Data Team to standardize design concepts for future design and development of electronic and electro- mechanical products built internally and by subcontractors. Some of the work produced spawned internal design improvements and cost reductions efforts.
• Zumwalt (NAVY Warship) Requirements Engineer
Served, proposed and originated requirements on the Zumwalt Naval System (Functional/Behavioral) Requirements Control Board (RCRB) and was part of the systems working group CPT (Cross Business Team) for (C3I) Command, Control & Communication/Sense (Radar & IR). Also, originated and maintained the requirements on the Design Build Process Specification (DBPS) for the Combat and Ship System. Provided requirements definition, traceability, documentation and design at the system, subsystem and component levels.
• As a AMRAAM Value Stream Lead, participated in cross-functional teams. Lead the Transition to Production for the AMRAAM Programs Office for all CCAs and RF, Microwave, Digital, Analog Modules /flex cables– improved yields from 40 to 98 percent during production. Implemented cost reduction, productivity and quality improvement programs saving over $3M which resulted in follow on production contracts
ADDITIONAL RELATED EXPERIENCE
MICROWAVE ASSOCIATES (M/A-Com) – Burlington MA
Mechanical Design Engineer
Designed, developed and manufactured RF Subsystems and components. Built and produced rotary joints, couplers, mixers, switches, filters, antennas, receivers, cable assemblies, amplifiers, isolators, oscillators, RF modules, phase shifters, shielding, power dividers, SAW devices, substrates, millimeter wave products and MMIC based on internal, defense and commercial contractors requirements.
Education: University of Massachusetts, Lowell, MA
Bachelor of Science in Mechanical Engineering Technology
Clearance: SECRET
Company & Professional Certifications:
Pro E EVMS 2 (Earned Value Management System 2) Six Sigma/SPC
Lean Manufacturing Motorola Design for Manufacture BOEs/DOE
Foreign Object Elimination Information Technology Awareness ISO 9000/AS9100/AS9102
J-STD-001D PDM (Product Data Management) IPC-A-610D
MlL-STD-883 MIL-STD-810 ISO 13485 FDA 21CFR820
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