Engineer Project Manager

Joao I. Castro

Summary of qualifications

**+ years of experience in ISO 9001 manufacturing environment

8+ years of hands-on quality experience

6+ years supervisory experience (technicians, production workers)

2+ years leading Six Sigma Green Belt and Lean Manufacturing projects

2 + years as Supplier Quality Engineer

Certificate of Quality Management (In process)

5+ years working with ASME BPVC, Sections II, II, VIII

Outgoing & excellent organizational and communication skills

Energetic self-starter, highly assertive, leader of cross-functional teams with a proven track record

DOE, FMEA, Six Sigma, Lean, SPC, GD&T

Education Rensselaer Polytechnic Institute – Troy, NY 1993

B.S. Mechanical Engineering

Work Experience Tyco Valves & Controls – Mansfield, MA April 09 – Oct 11

Project Manager/Quality Engineer

Successfully managed CVN78 valve development project and provided leadership to multifunctional team consisting of QA, QC, Manufacturing, Engineering, Government Source Inspector, and Purchasing

Presented detailed CVN78 project schedule and status to customer team during bi-weekly hi level meetings

Successfully led Six Sigma Green Belt project that saved company $50K/year

Defined and started two other Six Sigma Green Belt projects

Responsible for timely resolution of customer complaints and CARs (Corrective Action Requests)

Coordinated timely disposition, approval, corrective action, and closure of MRN (Material Reject Notice)

Wrote qualification test procedures including 1st Article, Capacity, Shock and Vibration

Wrote and maintained Quality Assurance Plans (QAP) for level 1 and non-level 1 pressure relief valves

Created BOMs and Valve Assembly Test Instructions (VATI) with clear customer requirements flown down to suppliers and assembly personnel

Successfully managed resolution of Vendor Information Requests (VIR) from customer by making sure QA documents, MRP, drawings, routings, VATI, and assembly procedures were changed as required to satisfy approved change

Coordinated scheduling and provided support during qualification testing at vendor test facility

Provided technical support during testing and assembly of all CVN78 prototype and production valves

Provided timely submittals of Welding, NDE and qualifications test procedures for customer approval

Lytron – Woburn, MA 2005 – Feb 09

Applications Engineer

Main responsibility to provide expert technical support to customer, outside sales, end-users, channeled partners and inside sales

Authored numerous technical articles and service documents for use by customers as well as internal sales, engineering and academia.

Was integral in securing several key accounts including contracts with Pro-Drive, Phillips, Northrop Grumman, Lockheed Martin and Fluid Management

Created and verified sizing tools and technical content of company web site and product catalog

Provided technical support during sales meetings with customers

Provide customer plant tours

Provide after-hours technical support and troubleshooting assistance for all cooling systems

Mectrol Corp. – Salem, NH 2003 - 2005

Product Applications Engineer

Main responsibility to provide expert technical support to customer, outside sales and inside sales for speed planetary and Dojen speed reducers

Work closely with European counterpart to improve product designs

Created BOMs, drawings, and routing for Planetary and Dojen product lines

Wrote Siemens Motorized Roller Assembly procedure that was awarded perfect score during customer audit

Designed easy to use assembly and end of line testing fixtures

Created bearing pocket, bolt hole sizing, and engineering release excel tools

Provide technical support to manufacturing and production

Yarway Corp. – Plymouth Meeting, PA 2000 - 2003

Quality Engineer

Responsible for ensuring customer requirements, as well as regulatory and industry standards were adhered to during design phase and production

Responsible for updating quality documentation including SOPs and QAPs

Responsible for maintaining quality training records

Created excel applications guideline tool to simplify valve sizing and selection process based on previous history

Coordinated the design and engineering release of custom valve orders to manufacturing

Durabla Fluid Technologies – Lionville, PA 1999 - 2000

Product Development Engineer

Managed HI-100 and Hi-Flow severe service control valve product lines

Implemented ISO 9001 design control and trained engineering department

Designed extensions of HI-100 and HI-Flow for specific applications based on fluid compatibility, customer specifications, ASME BPVC , and engineering principles

Performed stress analysis, valve and actuator sizing, and material selection based on customer specifications

Created BOMs, routings and drawings for all valves

Coordinated and supervised assembly and testing

Led effort to standardize valve product line based on 80% repeat business in specific applications within the power industry.

GE Astro/Lockheed Martin – East Windsor, NJ 1993 - 1999

Lead Mechanical Engineer

Managed all integration and mechanical testing of DMSP 5D-3 series, S-17 satellite spacecraft

Reduced defects by 35% from previous spacecrafts by working closely with other lead engineers to find root cause and implementing corrective actions

Wrote and maintained Fabrication Test procedures and Flow Alteration Procedures

Provided cause, disposition, corrective action and coordinated with MRB (Material Review Board), the timely closure of all spacecraft defects

Responsible for the scheduling and supervising work of two technicians

Assisted in the pre-launch integration and final testing of series 5D-2 series, S-13 spacecraft at Vandenberg AFB

Successfully completed prestigious Technical Development Program (TDP) which included a year rotation in Supplier Quality Assurance and Thermal Design and Analysis

As an SQE, managed Olin Rocket Research Company thruster supplier

As a thermal design engineer, performed thermal design and analysis of ADE and other spacecraft black boxes for EOS satellite. Also presented reports during PDR and CDR

Software Advanced MS Office, some MS Project, Solid-Works, AutoCAD, and Minitab

Languages Fluent in English & Spanish, advanced in French

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