Experience

BWI CHASSIS DYNAMICS (NA), INC.

• United States
• 1 - 100 Employee

• Senior Lead Test and Validation Engineer

  • Jul 2008 - Present

  Systems and Applications • Products: Controlled Brake, Controlled Suspension, Electric Park Brake, Brake by Wire, Pneumatic and Hydraulic lift systems • System Level EHCU testing, programming and calibration • Technical expert liaison between Product and Manufacturing Engineering teams • Validation Plan Creation of system and component with reliability and confidence targets. HALT and S/N test plan generation • Expert sensor selection and application • Design of Experiments problem solving and product comparison • Interview and actively recruit engineers and technicians • Mentor and train supervisors, engineers, technicians, and interns System Architect and Programmer (Hardware and Software) • Expert LabView (25 years) programmer (Real Time and Windows) • Hardware in the Loop (HIL) and Software in the Loop (SIL) utilizing MATLAB Simulink for controlled brake and suspension applications • Twenty complete Windows and Real Time DAQ control systems created from scratch (concept, schematics, drawings, appropriation request, hardware, software, debug and maintenance) • Developed and standardized test control software to emulate ECU logic • Complete documentation and software version control (TortoiseSVN) • Managed and lead team to implement tester designs and deployments • Performance tester run-permissive system database integration Expert Test System Hardware Integration • DAQ: PXI, Linux embedded, C series, SCXI, CompactDAQ, cRIO, FPGA, Real Time, ATI, GPDAS, SoMAT, CANalyzer and CANape • Servos and Controllers: Kollmorgen and Siemens servos, Brushed and Brushless motor controllers, valve, pneumatic and hydraulic controllers. • Sensors: Thermocouple, Thermistor, LVDT, Displacement, Encoder, Current Shunt, Non-Contact Capacitive, Flowmeter, Pressure, Torque, Strain Gauge, Force, Accelerometer, and Camera Show less



University of Dayton

• United States
• Higher Education
• 700 & Above Employee

• Adjunct Associate Professor

  • Jul 2010 - Jul 2012

  Taught DAQ and Test Measurement Class • ECT 408 which focused on sensors and data acquisition • Measurement error and problem solving • 20+ students/class • Hands-on, written exams, and speeches Taught DAQ and Test Measurement Class • ECT 408 which focused on sensors and data acquisition • Measurement error and problem solving • 20+ students/class • Hands-on, written exams, and speeches



Delphi

• United Kingdom
• Motor Vehicle Manufacturing
• 700 & Above Employee

• Senior Project Engineer

  • Jul 2002 - Jul 2008

  Simplified Electric Hydraulic Pump system to save $500K/year • Devised measurement system with high-speed video camera to solve chronic performance problem • Skilled electric and hydraulic system problem solver utilizing: DOE, Shainin Red X and Robust Engineering techniques • Experienced in design processes involving metal stampings, micro molding of plastics (PEEK, Nylon), cold heading and screw machining• Mentored engineers and technicians on test and design practices• Two hydraulic pump design patents. One defensive publication for contamination mitigation• Implemented pump systems through the full life cycle (BOM, FEA, DFMEA, PFMEA, and CR)Business workflow process team lead: data storage, software development, and training resulted in $300K/year savings• Refactored code into one application resulting in 200% increase in testing flexible metadata structure embedded in binary files (test history)• Paperless system resulting in improved documentation throughput• Automated durability software for a 400% reduction in test time Show less

• Advanced Project Engineer

  • Mar 1997 - Jun 2002

  Data Acquisition and Data Analysis• QFD/Score Card analysis used for software selection• LabView program created to analyze terabytes of data• Analyzed data applied to simulations, schedule correlation, component designs, and risk mitigation activities• Developed a non-contact capacitive dynamic rotor measurement system• Designed and Developed a Brake Noise Measurement Acquisition System for vehicle brake noise measurements. Accelerometers replacing microphonesImproved workflow process through analysis, data storage and training • Realized a $250K/year savings with this paperless solution • Refactored code from five different data analysis programs into one application • Improved analysis throughput with value stream mapping• Upgraded an Access database to Oracle 8i. Linux server with a PL/SQL web interface• Led team for a Java-applet validation and report system. Collected and displayed test data, reports, costs, timing, and decisions. Enabled dynamic executive reports with the touch of a button• Designed intelligent test selection system to direct engineers to proper tests Delphi Automotive Data Acquisition group• Created a common data format for the entire corporation• Initiated regular meeting to share best practices• Organized fleet-testing platforms to leverage strengths from each division• Served on Laboratory Information Management System review committeeISO 9000 work and test instruction policy group• Created, reviewed, and updated test/work instructions• Managed and developed thirty-five engineering technicians Show less



General Motors

• United States
• Motor Vehicle Manufacturing
• 700 & Above Employee

• Reliability and Test Development Engineer

  • Jan 1996 - Feb 1997

  Improved reliability and testing processes • Improved test software control and data analysis • Created Multiple Environment Overstress Test schedules for validation • Served as lead coordinator for western cooling trip: responsible for data collection, running test schedules and analysis • Instituted DFMEA, ISO 9000 and statistical analysis Improved reliability and testing processes • Improved test software control and data analysis • Created Multiple Environment Overstress Test schedules for validation • Served as lead coordinator for western cooling trip: responsible for data collection, running test schedules and analysis • Instituted DFMEA, ISO 9000 and statistical analysis



Eaton

• Ireland
• Appliances, Electrical, and Electronics Manufacturing
• 700 & Above Employee

• Engineer Co-op

  • Sep 1993 - May 1995

  Designed and implemented portable data acquisition software packages Developed environmental test plans for product validation Designed and implemented portable data acquisition software packages Developed environmental test plans for product validation