CV: Lead Engineer/ Sr. Program Manager


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Candidate Profile
 Date Submitted:20-07-2012
 Last Modified:21-07-2012 (07:41)
Job information
 Current job:Lead Engineer/ Sr. Program Manager
 Employment Term:Permanent
 Job location:Anywhere
 Date available:immediately
 Industry:
 KeywordsEXPERIENCE: 20+ years product / process development 20 years 3D CAD /Solid Modeling 18 years design engineering 10 years project engineering /program management 7 years FEA Various quality tools usage and exposure; DOE, SPC, 5S, 8D, FMEA, DFMA
CV

- Currently spearheading government projects on process engineering to increase the fatigue life and strength of critical engine components. Helping achieve the DoD’s goals of increasing fleet reliability and readiness by lessening dependence on maintenance, repair, and overhaul (MRO).
- Program Management, Leading National & International Teams (CFTs, IPTs)
- Government Program and Contract Management (DACP, SBIR, STTR, IDIQ, GWOT, GWAC, SLEP, RTOC, IBIF)

CAREER SUMMARY
Highly successful experienced program manager with outstanding experience gained through a series of progressively increasing responsibility of assignments and roles. Fully capable of managing the product development and program management process from idea conception to production implementation. Has a long record of success in propelling breakthrough improvements and bottom-line gains on business critical problems for companies and clients. Known for relationship-building with multinational clients and teams as well as cost-reduction strategies. Experience in the aerospace, aviation, defense, automotive, industrial, special machinery, plastics, and metals fields. Roles have included Engineering Management, Program Management, Project Engineering, Design Engineering, and Finite Element Analyst.

KEY SKILLS & KNOWLEDGE AREAS
Program Management
Proposal/Quote Development
Deliverables/Specifications Development
Manage / Minimize Project Risks
Fosters client relationships
Team Leadership
Customer interface/presentations
Project Engineering
Process Engineering
Process Optimization
Process Simulation (FEA)
Product Design & Development
Fixture / tooling Analysis & Design
System/ Component Analysis & Design
Stress Analysis (ANSYS)
Damage Tolerance Analysis
3D CAD (SolidWorks)
ISO & SPC Tools
GD&T, DFMA, FMEA
Statistical Tolerance Stack-Up
Microsoft Office Programs

EXPERIENCE
Lead Engineer/Sr. Program Manager; Lambda Research, Cincinnati OH 6/06 - Present
Manage 90% of the government’s procurement dollars and influence the management of over $5.0M in R&D revenue annually.
Hired to source and secure contracts with US DoD branches in support of the DoD's goals to reduce jet engine maintenance costs and increase fleet readiness. Regarded as one of firm’s subject matter experts (SME) on processes that increase the damage tolerance and fatigue life of critical components. Manage programs for various DoD branches, NASA, Pentagon, DOE, and OEM clients in the aviation, aerospace, defense, nuclear, and power generation fields with P&L responsibility on all programs. Work with all levels of management and client teams to drive consensus, collaboration and forward momentum toward the completion of project milestones and attainment of client goals.
• Developed and optimized engineering solutions for fretting fatigue and FOD on jet engine and combustor components, increasing R&D revenue 200% and production revenue 400% while assisting the DoD (NAVAIR) in achieving their maintenance, inspection and replacement cost reduction goals by over $10M per year.
• Report to the company president as engineering department manager with six direct reports
• Program Example: Managed $1.24 million Stress Mitigation System program for the U.S. Department of Energy
- Demonstrated/delivered system to prevent corrosion of nuclear waste container lids
- Delivered solution 5 weeks (10%) ahead of schedule
- Realized $248,000 (20%) cost savings for employer
• Submitted five concepts for patent applications
• Lead international and national teams, engineering and optimizing LPB technology for clients
• Design and development of three new LPB Wheel Tool designs; using CAD (SolidWorks), GD&T and DFMA tools
• Performed presentations to customers and upper management.
• Create and execute project work plans while effectively minimizing project risk.
• Establish and manage client day-to-day interactions and expectations and foster new client relationships.
• Ensure production implementation compliance with regulatory agencies (DCMA, FAA, ISO) and perform FMEAs.
• Work with clients to develop and perform V&V requirements.
• Participate in and lead teams in solving difficult technical problems.
• Relied on as primary trainer of newly hired engineers on process design, production implementation, and standards
• Support proposal/quote efforts by reviewing deliverables; providing proposal scope, cost, and schedule estimates
• Perform damage tolerance and fatigue life analyses (AFGROW), applied and induced stress analyses (ANSYS)

Sr Project Engineer; Project/Product manager for all centrifugal product lines, PennBarry Dayton OH 12/04-6/06
Global Engineering firm serving clients across the industrial ventilation industry.
Oversaw and lead multiple projects simultaneously in product development, current production, and cost reduction.
• Performed testing, prototyping, analysis, and program budget tracking
• Worked with plant operations / personnel to resolve quality issues during ramp-up of a new manufacturing facility
• Redesigned entire roof exhauster line using new manufacturing processes realizing $0.5M in savings per year
• Saved $1.0M in fixed costs by spearheading tooling specification, selection and delivery of automated machinery
• Designed/introduced into production new roof exhauster models to fill in competitive product offering gaps
• Identified savings/improvement opportunities and solved challenging technical problems
• Designed/developed new Axial Exhaust Propeller Fan unit to provide larger HP motor capacity than our competition
• UL793, 762, and 705 testing, certification and compliance on new product models and product lines

Program Manager and Analyst (FEA) Engineer; Essig Research Cincinnati, OH 3/02-10/04
Engineering firm providing analyses (ANSYS) for the aviation and aerospace industry.
Obtained project funding from clients on commercial & military programs, and tracked and met program budgets.
• Structural stress, deflection, and heat transfer analysis of complex systems; GE90 & F110 engines
• Increased jet engine turbine life using sensitivity trade-off studies from redesign & analysis iterations (Unigraphics)
• Completed over 30 repair engineering documents; fans, booster assemblies, rotating components, structures (CF6)

Development/ Analyst Engineer; GE Aircraft Evendale, OH (Laid off due to effects of Sept. 11th) 7/01-12/01
Global Engineering firm serving the aviation and aerospace jet engine industry.
Performed applied stress and thermal analyses of combustor components on commercial and military applications.
• Performed analyses (ANSYS) on the F110, CF34-8C, and GE90-94B engines

Product Development & Design Engineer; Parker Thermoplastics Englewood OH (Facility Closed) 7/00-4/01
Custom Injection Molder Engineering firm
Developed injection-molded components for complex molds and secondary plastic assembly processes.
• Performed FEA stress analyses all new designs & developed fixture designs for automating manufacturing processes
• Interfaced with suppliers to ensure adherence to schedules, supplier development & ease of manufacturing
• Worked with customers to ensure compliance to APQP and PPAP standards and performed 8D & FMEA techniques
• Co-developed a two-shot auxiliary brake booster design with Delphi Brake Systems using Unigraphics
• Submitted a proposal for a patent application on CV joint sealing technology
• Saved $0.7 M in costs by introducing a new cost improvement procedure that reduced mold change-over time

Sr Design Engineer; Valeo Automotive Inc. Kettering, OH 6/93-7/00
Tier I Global Company of Engine Cooling Fan Systems for the Automotive Industry
Developed from concept to production, complex hydraulic and electrical automotive engine cooling systems.
• Promoted 4 times in 6 years and received 3 patents in 5 years
• Managed and trained six designers, tracked engineering changes and designs to timelines
• Designed injection-molded shrouds and fans (over and insert molding), using Unigraphics
• Performed prototype, production volume, test fixture design, and stress and deflection analyses
• Included project engineering, requiring heavy oral & written communication with customers and suppliers
• Submitted cost improvement initiative resulting in a savings of over $0.5 M per year
• Developed low-mass cost-effective designs resulting in over $1.8 M plastic material savings per year
• Developed and integrated a new technology and product involving hydraulic engine cooling. Used 8D & DOEs.
• Redesigned hydraulic motor, manifold, and components to achieve a 35% cost reduction prior to production release
• Developed engine cooling fan to shroud interface changes that achieved a three percent increase in efficiency
• Brought over thirty platforms to production in seven years per APQP and PPAP requirements

Mechanical Designer; Hughes Aircraft Tech. Center Carlsbad, CA - SECRET Security Clearance (Inactive) 4/87 -6/93

EDUCATION
University of Dayton; Bachelor of Science, Mechanical Engineering Technology 1999
3.94 GPA, Summa Cum Laude (90% of credit hours earned under BSME program)
Palomar College, CA; Associate, Technical Design & Drafting 1988
3.6 GPA (both degrees earned at night while working full time)

PUBLICATIONS
2011 P-SAR Conference: Damage Tolerance Improvement of the F100-220 Fourth Stage Compressor Blade by
Low Plasticity Burnishing


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