CRE Ralph J. Capan

I have reviewed the description for the senior Reliability Engineering Position. I find that I can meet all of those requirements. I have listed below those reliability activities which are relevant to your requirements form this position.

My resume is attached.

I would like to be considered for the Reliability Engineering Position. Over the past 30+ years, I have worked on all types of products. My Resume is attached:

Calculators (TI), computers (TI), advanced communications systems (ITT), avionics guidance systems Delco, automotive transmission (FORD), and complete automotive mechanical and electrical systems (Ford and GM).

Worked in the military, commercial, and automotive industries,

Familiar with the past MIL-STDS and SAE

Extensively familiar with the new wave in the Reliability Engineering Field of incorporating Robustness into the design up-front (Ford, Visteon, and GM),

Taught P-Diagram and Robustness matrix creation and use for over 4 years while at Ford and Visteon (I have taught this course to both engineers at Ford / Visteon and suppliers alike),

Familiar with the use of Six Sigma (Ford, GM, Visteon)

Passed the IFQ Six Sigma exam at the Master Black Belt Status on the first attempt (Visteon),

Worked in both the engineering arena and in the manufacturing environment,

Assisted in been the Team leader in starting up three FRACAS systems, two major and one minor (ITT, Ford, and Delco),

Conducted FRACAS analysis (ITT, DELCO, FORD),

Wrote Reliability Program Plans (ITT, DELCO, FORD, Magna, BAE),

Performed Warranty Analysis at FORD,

Team Leader for TAAF / Reliability Growth Testing,

Increased thoroughness of DFMEA by 75%,

Reduced DFMEA Preparation time by over 50%,

Wrote Reliability Test Procedures (ITT, FORD,

Wrote Reliability Test Reports (FORD, ITT),

Performed Thermal Analysis (ITT, FORD),

Performed Reliability Predictions using RELEX (BAE Systems),

Wrote ESS Reports (DELCO),

Taught DFMEA (FMEA) classes to engineers and suppliers at Ford, GM, and Magna,

Wrote Critical Item Control Plan (ITT),

Generated functional block diagrams (FORD and GM),

Conducted Reliability Growth Testing (ITT and FORD),

Used functional Block Diagrams as a roadmap for the generation of DFMEAs,

Spear headed the use of System Level DFMEAs at Ford,

Conducted reliability analysis on a Power Supply at ICL,

Wrote HALT Plan at Ford and ICL,

Wrote HALT Test Procedure at Ford and ICL,

Wrote HASS Plan at ICL,

Team Leader for Growth Testing,

Wrote HASS Procedure at ICL,

Prepared reports and made presentations to senior management, suppliers, and Government Program Managers,

I have worked as an engineer, team leader, Supervisor, Department Manager, Reliability Program Manager, and Staff engineer.

I feel that I have unique qualifications in the reliability engineering field that is also applicable to the quality engineering field in any industry. Please give me a call and we can discuss your needs in more depth and of how I can be of assistance to your organization. You can reach me at 810-***-**** (cell). I look forward to your call. You can also reach me at the following e-mail address (*******@*****.***).

Sincerely,

Ralph J. Capan

Ralph J. Capan

8384 Oak Shade Court

Davison, MI 48423

*******@*****.***

810-***-****

ASQ Certified Reliability Engineer # 2990

SYNOPSIS

I am a Certified Reliability Engineer and able to manage a comprehensive reliability program from product inception to end of life. Experienced in the aerospace, automotive, commercial, military and supplier industries. Products have included: electronics, computers, advanced communications systems, electrical, avionics, guidance and space systems, electro-mechanical, automotive transmissions, and complete automotive electrical systems . Experience with MIL-STDS and SAE Standards. Passed the IFQ Six Sigma Exam for Master Black Belt Status on the first attempt. Extensive experience using and teaching Reliability Engineering Techniques to incorporate Robustness techniques up-front into the design. Experience in establishing FRACAS and writing Reliability Program Plans, Procedures, Reports and CDRLs.

TECHNICAL EXPERTISE

Reliability Predictions FRB, FRACAS, CCB Reliability Testing.

Reliability Allocations FMEA, FMECA, FTA, DFMEA, PFMEA Proposal Preparation

Reliability Program Plan Liaison / Customer interface Vendor Qualification

Reliability Program Management Reliability & Robustness Techniques Field Service Engineer

Warranty Analysis ESS, Reliability Modeling Reliability Modeling

Reliability Test Plans, Procedures, and Reports (TAAF,/RDGT, RQT, PRAT) Kano Modeling

Reliability Program Management Reliability & Robustness Techniques Weibull Analysis

Maintainability Predictions LSAR

Quality and Reliability Consulting 11/2009 – 11/2011

Reliability Risk Management Specialist Quality & Reliability Assurance

• Used Meridian S/W to monitor Plant Maintenance. Designed predictive maintenance and/or condition monitoring tools for Wind Turbine Generator and Power Generation and software.

• Demonstrated Reliability Prediction Analyses utilizing Methodologies such as MIL-HDBK-217F, PRISM, 217-Plus, on Turbine components.

• Complete development life-cycle requirements, design, testing and qualification to the requirements GD evaluation and CMR reviews

• Performed and lead analyses and derived subsystem allocations for Turbo-Machinery, Compressors, Pumps, and Rotary Equipment.

• Applied Reliability Analysis to Power Inverters and Electronic Distribution.

• Utilized historical data to forecast forward using reliability predictive methods to design RCM for service improvements

• Responsible for the information and prioritization of service productivity and reliability projects while balancing GE internal metrics with the customer needs

• Wrote a HALT Test Plan for a new Gaming System.

• Responsible for characterizing and modeling the root cause of the variance to the product reliability and removal entitlements

• Worked closely with Service, Engineering and Region Fleet Managers to ensure field modifications are being executed to engineering standards.

• Utilized Software Packages such as RELEX, FTA-Pro, PHA-Pro, FMEA-Pro, Doors, SAP, Nexus, Meridium, etc

• Planed, specified, designed, and managed projects to fulfill customer requirements.

• Procured new equipment in support of company products and processes. Fixed and Rotating equipment.

BAE Systems – (Contract) 1/2009 – 6/2009

Reliability Engineer

• Performed Reliability Prediction on 3 variants of MRAP using RELEX

• Introduced the Reliability and Robustness concept

• Forwarded Reliability Predictions to the Maintainability Department. Assisted the maintainability engineers in completing the LSAR Form.

Self employed 1/2007 – 1/2009

Running my own business “Stor and Lock” in Mt. Morris MI.

Magna Donnelly Electronics 12/2005 – 1/2007

Technical Specialists Reliability Engineer

A Tier 1 supplier of electronics to the automotive industry

• Established Reliability Program and wrote Reliability Program Plan

• Standardized DFMEA procedure; taught classes and assisted in writing DFMEAs

• Introduced and taught classes on Robustness and set up P-Diagrams for 4 products

• Interfaced with the customer on DFMEAs and all Reliability Related Matters

• Reviewed RFQ documentation and made recommendations for changes

• Established methodology to evaluate Reliability Growth Test data

• Taught Fault Tree Analysis Classes

• Assisted in setting up Design Guidelines for engineering

FORD / Visteon 4/1999 – 5/2005

Product Design Engineer

A Tier 1 supplier of axle driveline systems to the automotive industry

• Team leader in EESE implementing reliability and robustness techniques to resolve durability issues

• Saved the company millions of dollars by identifying and resolving critical reliability issues during Target Agreement negations. This reduced the number of full test vehicles from 98 to 16.

• Provided technical and statistical support in resolving manufacturing issues related to axle preload

• Prepared detailed interface and block diagrams on 12 axle / drive-train programs that allowed for dull weighting of the interfaces with components and acted as a roadmap for DFMEA Development the Block Diagrams increased DFMEA thoroughness 10 times and resulted in a reduction of over 70% in DFMEA development time.

• Conducted training classes on Ford required Reliability and Robustness initiatives (P-Diagram and Reliability and Robustness Matrix)

• Represented the company and successfully interfaced with customer an all reliability issues. Presented evaluation reports to 2 chief engineers at Ford.

• Failure Analysis of Field Failures

• Identified numerous issues during a “Fresh Eyes Review” and followed up on corrective action with engineering

• Reviewed warranty data and reviewed failure data to determine root cause for resolution of warranty, customer satisfaction and durability issues

• Prepared reports for upper management

Ford Motor Co. (Contract) 4/1993 – 12/1996

Reliability Implementation Engineer

• Responsible for implementing reliability techniques into front wheel drive vehicles

• Recommended improvements to the FRB process. The FRB Process utilizes Ford’s 8D system as one tool to identify corrective action.

• Instrumental in selecting corporate growth test methodology to analyze and present test data.

• Conceptualized the PTO FRACAS Data Base This database serves as the benchmark for the Ford worldwide FRACAS warranty data base

• Performed an evaluation on the Lincoln Continental wiring system that led to correcting moisture problems in connectors

General Dynamics - Reliability Engineer (Contract) 9/1989- 3/1993

• Reviewed, assessed, and categorized track test incidents on M1A1 tanks on 5 durability tests

• Maintained a database to correlate government test data with previous similar test data

• Conducted incident investigation on failed track pads and road-wheels

Delco Systems Operations (Contract) 4/1988 – 9/1989

• Managed all reliability activities in five programs

• Interfaced with customer on all reliability activities

• Responsible for the operation of FRACAS final reporting to the customer

• Participated on CCB (Change Control Board)

• Chairman of the FRB (Failure Review Board)

• Review and approved FMEA prior to delivery to the customer

• Developed a generic ESS (Environmental Stress Screening) Report for a sixth program. This report was used on a seventh program, This ESS Report demonstrated the effectiveness of Burn-In in reducing infant mortality. This report was developed during acceptance phase of production and was forwarded to the customer on a monthly basis.

ITT Reliability Manager 9/1984 – 3/1988

• Supervised 6 employees

• Managed all reliability related production related including PRAT on SINCGARS. Wrote the First Article PRAT Report.

• Developed and implemented a TAAF Test Plan and Procedure

• Performed data analysis and prepared reports for upper management. Conceived and directed the integration of the TAAF, FRACAS, and FRB data bases.

• Assisted in the establishment of FRACAS for SINGARS Army Radio System

• Performed a FMECA on the Audio Frequency Module

• Participated on a TIGER team to resolve a flow soldering issue causing electrolytic capacitors to fail

• Participated on another TIGER team to resolve the alignment of SMD on PWBs during assembly and the repair operations

• Developed separate and generic test plan that was used as the basis for subsequent test plans on other programs

ADDITIONAL EXPERIENCE

International Computers - Wrote a generic letter from the president of ICL to the presidents of our suppliers on the poor performance of their products. 9/1983 – 8/1984

Texas Instruments 8/1980 – 8/1983

American Institute for Professional Education (part time while in college) 5/1979 - 7/1980

MILITARY

US Air Force 4/1972 – 6/1977

Honorable Discharge. Sergeant. Ground Radio Equipment Repairman (304X4).

Repaired and maintained Air Traffic Control Communications Equipment, ROMAD

EDUCATION 8/1977 – 7/1980

BSEET – Pittsburg State University; Pittsburg, KS 1980 GPA - 3.48 / 4.0

Continuing Education

College level Courses in Managerial Accounting, Introduction to Management, Business Writing, Reliability Engineering, Dale Carnegie Course on Public Speaking, QS-9000 ISQ-9000 Lead Auditor, Reliability Statistics, Failure Analysis Class.

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