Carl Mcilheran Email and Phone Number

Managed Inservice Test (IST) and Appendix J test programs for Braidwood Nuclear Generating Station. Led IST 4th Interval program update to ASME 2012 Code compliance, including supplemental position indication compliance testing implementation. IST and Appendix J qualified.

• Led cross-functional team to introduce an NPI program into production on time, which included the installation and qualification of two new machines in the production facility• Led team to resolve pre-launch manufacturing issues for roll-formed sheet metal products• Managed seismic validation testing program• Coordinated control system updates on a new machine cell

• Redesigned hydraulic systems on two Rotary Blasthole Mining Drill platforms for Tier 4 NPI programs; achieved 30% cost savings, with increased performance• Developed system performance requirements based on input from Marketing, Field Service, and vehicle test data analysis• Led team of 6 component engineers plus additional cross-functional team members to develop optimal component and sub-system solutions, weighed make vs buy decisions• Brought hydraulic team on track to design and deliver Pilot Production components in 14 months, which was 50% faster than normal NPI programs

• Led cross-functional NPI teams typically consisting of 2-4 design engineers plus Manufacturing, Quality, and Purchasing personnel (total of 8+) that developed valves for 40 machine models on 6 different machine platforms• Developed multi-generational product plan strategy for components on several platforms• Executed make vs. buy decisions, performed NPV and discounted cash flow analysis, developed capital estimates, negotiated with suppliers, negotiated budgeting, negotiated transfer pricing, developed and drove timelines • Presented approximately 12 NPI gate reviews to management per year, plus other reviews for cost reduction programs• Improved NPI management process to increase effectiveness• Mentored junior engineers in design and NPI processes• Led NPI teams to consistently achieve cost, quality, and on-time delivery goals at first production• Led 10 NPI programs in 2014 with $28M extended value, which was $1.2M (4.2%) less than cost target.• Introduced a redesign to a Motor Grader implement valve that provided $1 million in annual variable cost savings• Introduced a new steering valve that replaced a warranty-prone valve which had caused over $1M in warranty• Saved approximately $750k in capital on a new steering valve by outsourcing the finished machining• Conceptualized a new steering valve that would save approximately 25% in cost• 2 patents granted, several more in process for products in Articulated and Mining Trucks• Received Executive leadership recognition as I led the Motor Grader Valve team to win the 2014 Chairman's Award for Product Quality Improvements

• Led Six Sigma Black Belt projects to address field failures, manufacturing issues, while also serving as the design engineer for the projects, using Pro/E (Creo)• Used DFMEA’s, FEA, 8D, Weibull, field data, lab endurance testing, on-machine test to verify root cause, and validate solutions • Resolved ride control pump check failures on Wheel loaders by implementing more robust design and removing hose clip. $880k value prop • Redesigned dual-set relief for hoist valve. $40k value prop• Modified cartridge designs on a valve manifold. Reliability increased by 9x. $104k value prop

• Developed new hydraulic valves with suppliers and system engineers using Pro/E for several vehicle platforms• Resolved initial design and manufacturing production issues on Motor Grader Steering Valve • Successfully executed design reviews and gate reviews for valves on NPI programs• Combined tow valve sub-circuit into a single valve, which saved ~$200 per machine

• Designed solenoids for new industrial, commercial, truck and off-highway markets; executed lab validation, and introduced to production in US and China facilities• Developed cost estimates, and submitted quotes to potential customers• Designed and built a sample in two days, which led to a new division's first major customer ($100k+ order)• Developed new performance spec that targeted non-traditional applications, and published to company product catalog

• Designed radiators, oil coolers, and heat exchangers for automotive and truck platforms • Collaborated with automotive customers to determine requirements, and to address field/factory issues• Performed FEA analysis to optimize radiator and turbo cooler designs• Developed lab validation plans to prove out endurance requirements• Used wind-tunnel testing to prove out proposed cooling systems to optimize component selections and placement • Developed DFMEA’s, DVP&R’s and other APQP per ISO9000 and QS/TS standards