Quick to learn new concepts and pick up new skills, my determination, creativity and positive team oriented attitude have lead me to great success in all of my careers thus far.
Design Engineer at Caterpillar:
In December of 2014 I was hired as a contract engineer at Caterpillar in their low voltage electric drive group in ACSD. As a design engineer on the component team I was responsible for the rotors and stators for 90-500KW generator and motors. The designs were new product introduction requiring the engineering and drafting specifications to be developed by the team as we progressed.
My roles included:
- Modeling and drafting of design changes/updates
- Working directly with various suppliers to procure prototype build materials on time and to spec
- Write and develop programs to control the winding machine for the production of stator coils
- Physically assemble prototype rotors and stators
- Assist with test stand assembly
- Failure inspection and root cause analysis
- PFMEA/DFMEA creation to identify, categorize, and institute preventative actions to mitigate risk
- X-ray analysis of coil design to asses production technique quality and failure risk.
- Performed electrical check out tests such as resistance, capacitance, inductance, surge testings, megger, current leakage, and many many partial discharge tests.
- Helped develop industry leading partial discharge testing procedure
- Created statistical analysis tools for stator insulation systems
Quality Engineer at Kress Corporation:
When the projects I was lead for in engineering were winding down and moving into production a vacancy opened up in the final quality inspector role at Kress. With my experience as an assembler, in engineering, and spending time at various customer sites it was decided I was the most qualified candidate for this role. My initial responsibilities were to supervise the build inspectors and the in process inspections of the products along with personally performing the final testing of all equipment. The timing worked out that I was moved into the position just as all of the major product lines were switching over to the tier-IV final emission designs and it was required to create new test procedures and documentation. Once I became familiar with the inspection and check out processes there was a reorganization of the quality department that had me directly reporting to the director of quality and my title was changed to quality engineer, of which I was the only one at the company.
My roles included:
- Supervision of and verification of in process quality checks.
- Liaison between quality, production, engineering, and product support.
- Create and document validation procedures for new generation of products, coal haulers, slag pot carriers, slab haulers, straddle carriers, etc.
- Recommend design changes for engineering based on
- Redesigned the slag pot carrier prime mover hydraulic routing eliminating many hoses and points of failure. When transitioning to the tier IV final generation of prime movers the hydraulic system became more complicated with the remaining fixed displacement hydraulic pumps being replaced with variable displacement pumps. The previous routing had dozens of hydraulic hoses, all with a stainless steel braid covering. This caused the assembly and quality check out process to require many hours to properly constrain the hoses so they wouldn't contact each other and cause damage overtime. The new design I created replaced most of the sections of hose with parallel tubes that could be assembled into one assemble before being installed. This design took full advantage of the companies new CNC tube bender to significantly decrease assembly time while making a much simpler to qualify and more durable final product, decreasing cost.
- Created and implemented new visual deviations process to greatly improve the speed and accuracy of communication between the quality department and production for each machine.
Lead Engineer at Kress Corporation:
After nine months of working as an assembler I was moved into the office to do basic drafting and design work. In under two weeks I had taught myself to use Unigraphics NX 7.5 and enough of their engineering and drafting standards to work with little supervision. In less than six months of being in this role I was given the responsibility of being the lead engineer on a slag pot carrier. Shortly after I took on the tundish carrier project, which is a product that had not existed before. Starting with just the sales contract and some guidance from the engineering management, product support, and sales I developed my own concept for the design. All of the projects I was responsible came in under budget and ahead of schedule while I was able to incorporate more improvements than were required. My roles at Kress were ever expanding including:
- Structural FEA
- Hydraulic/pneumatic plumbing modeling and drafting
- Weldment modeling and drafting
- Shop Liason
- Performing site visits to work with customers on machine improvements and verifying product requirements
- Linkage force simulations using custom python coding I wrote myself
- Hydraulic schematic creation and updating
- Verifying modal analysis results using acceleratometer vibration data to determine natural frequency of structures and the excitation frequencies.
- Created structural reinforcement packages to be sent to the field based on collaborating with the FEA team and their modal analysis results.
- Redesigned structural elements based on customer feedback and discussions with the welders to significantly improve strength while requiring few machining steps and greatly easing the burden on the welders. I performed FEA to verify and fine tune the structure prior to release to production.
Envisioned new Kress product that solved major customer issue. Designed and brought to production in less than 10 months. The typical steel mill process of continuous pouring was causing a safety and environmental issue by pouring mid-ladle excess steel on shop floor in the mill--creating a considerable amount of airborne debris as well as molten splash. Devised a unique solution to hold and position container to be picked up by a modified slag pot carrier and dumped at a remote location. Performing the majority of the work on this project myself I was able to deliver the final product well below budget and ahead of schedule. This product is being implemented at one location now and being investigated by two other sites.
Assembler at Kress Corporation:
I began my career at Kress as an entry level assembler . I took to this job immediately; in the normal time they would use to train a new assembler I had become one of the top assemblers. As someone working to move into engineering as soon as possible this made my time in this position extremely valuable. With this mindset I approached ever new task as an opportunity to learn as much as possible. Because Kress makes mostly semi custom equipment with a relatively small and highly skilled workforce I was performed many wildly varying tasks providing me with hands on experience at all points in the manufacture of the equipment.