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Tier I transfer case supplier for passenger vehicles.Design, validation, and release of single speed transfer case. Customer interface, supplier interface, inter-company team interface for testing and production support.• Customer interface design reviews for overall package performance and test results according to the specification document• Coordination of prototype component procurement, build, and verification testing• Supplier reviews for production level componentso Develop and refine statement of requirements for supplier-designed components, ie: seals.• Inter-company production team reviews for assembly• Inter-company team reviews for design and performance of overall package and individual components• Test reviews and teardown inspection / analysis• Investigations of test anomalies, Root Cause Analysis

Tier I axle design and production for passenger vehicles.Production design of rear drive module housings and power transfer units. Design, validation, and release. Customer interface, supplier interface, and production support. Focused involvement with high pressure die cast aluminum housings.• Coordinated with customer to design, validate, and implement housing changes.• Led interdepartmental team to create and validate design, reviewing FEA and Magma simulations.• Worked with interdepartmental business team and suppliers to define design requirements and reduce manufacturing costs.• Supported production with machining modifications to maximize use of common tooling.• Reduced porosity issues by 61% and 27% for the two most common areas, as well as several other areas of reductions in the range of 10–15%.• Reviewed and revised specifications according to part use and component interface.• Performed GD&T stacks with RSS to confirm production machine stock.

Independent Suspension Axles for heavy off-highway trucks.Prototype axle design and assembly, as well as production support, quality support, and aftermarket support. • Coordinated with major customers to refine axle performance for military vehicles.• Completed prototype axle rebuilds – post-test axle examination, rebuild, and documentation.• Responsible for completion of Bill of Materials for production axles. Directed design team in complete revision of components/drawings from European to North American build.• Support Quality in off-site axle rebuilds.• Performed test data analysis and provided report of known forces for comparison to FEA data.• Worked with suppliers to research lightweight component options.• High level of customer interface and company representation.

Clutch Division:Worked with Tier I automotive customers, off-site manufacturing personnel, in-house build shop, and in-house Metallurgist in design of clutch products.• Maintained day-to-day customer support by providing designs, calculations, and educating customer regarding clutch interface and characteristic details.• Refined DMFEA to specific application and presented to panel of customer engineers.• Built, tested, and classified components by torque application for reference in accurate and timely clutch design.• Documented clutch design parameters for maximum strength, minimum material, and minimum machining/assembly to reduce product cost, design time, and to eliminate design oversight.

Responsible for clothes dryer advanced product development, including prototype design, construction, and testing.• Built and tested prototype dryer with spray capability.• Documented components, sources, specifications, and fluid flow design.• Introduced team to use of Bernoulli equations in pipe / sprayer applications.

Completed design and build of one internal combustion engine and two mini-turbine generator packages. Responsible for prompt reports of design and cost in support of Sales and Application departments.• Successfully designed and built 830kW IC engine generator package with full heat recovery system from conception through shipping. Identified site requirements, specified and sourced components, performed airflow, fluid flow, pressure calculations and lifting and transport logistics for on-time delivery to customer. • Achieved 10% reduction of company expenses through negotiation and tracking of costs. Provided clear and accurate reporting on design, materials and services.• Reduced 12 power generation packages to four common platforms, lowering cost and design time. Created standard drawing numbering and revision system, reducing the file tracking and retrieval time by 75%. Defined order of assembly to expedite future production processes.• Supervised contract personnel and mentored co-op students for design and build of prototype units.