David Gray Email & Phone Number

Johnson City-Kingsport-Bristol Area

Johnson City, Tennessee, United States

Johnson City, Tennessee, United States

 Designed solid models of tanning beds for production line to include aluminum extrusions, vacuum formed plastic and injection molded plastic. Design required creative form for visually stunning appeal to customer. Managed construction of 3 commercial models and 5 consumer models including production lines. Developed method to use knowledge from hand-crafter of hot tubs to solid model & transfer comfort to new design while adding more innovative visual appeal. Designed innovative manifold design to incorporate a vortex operated heating element. Worked with FEA contractor to ensure proper strength & geometry in injection molded parts.

Bristol, Tennessee, United States

 Planned and budgeted for new 100,000 SQFT, multi-million dollar manufacturing facility. Project Managed installation of $3.5M printing press purchased from Germany. Responsible for engineering supports for 42 different production lines. Designed 5-color flexographic printing press w/ 30HP motor & segmental driveshaft, 17MPH operating speed. Managed teams of maintenance crews for assembly of new presses & PM’s on existing equipment. Designed several board presses w/ 4’ dryer-(designed mechanical components, HVAC & pneumatics) Developed patented, Innovative ink delivery system that surpasses all competitor models & LOW cost. Designed 2, 2-color tail end printers to use custom print cylinders. Redesigned all gearing drawings for proper backlash and manufacturing specifications. Designed & project managed installation of high volume compressed air distribution system-both plants (complex storage & drying system) 325HP, system saves company $20,000 minimum per year w/ reliability & efficiency. Designed chilled water system for Bristol plant, 50 tons. Responsible for all TDEC/DOT/EPA compliance, training and reporting plus waste reduction. Created repair & operational manuals for presses. Introduced assembly drawing concept for presses, revamped drawing numbering system, developed engineering & CAD manuals for department. Graduated supervisory/Leadership seminars presented by Tuck Management Group

Piney Flats, Tennessee, United States

 Reverse engineered high profile engine, airframe & power transmission parts to supply Delta & U. S. Airways overhaul & repair facilities in Multi-Million Dollar Programs with high liability exposure. Prepared production costs for parts considered for manufacture.  Contracted with MECA Engineering, Kingsport for design of HVAC systems (churches, schools & offices) & Electrical CAD layout. Included load calculations, duct & unit sizing with Trane design software. Contracted with Master Model Craft, Bristol to design rotary indexing pallet system for John Deer tractor hoods, mower body assembly Station with hydraulic hole punches & engine assembly palletizing system.

Piney Flats, Tennessee, United States

 Assisted with FAA/PMA processes for reverse engineering engine, airframe & power transmission parts to supply Airline overhaul & repair facilities. Prepared shop drawings and assisted with tool path programs.

Bristol, Tennessee, United States

 Responsible for management of finances of $1M including balance sheet, profit & loss statement, & cash flow. Managed $400K finances for subsidiary masonry contracting business with payroll on twenty personnel. Duties included management & training of technical staff of 23, preparation of engineering & sales reports. Designed a wheel mounted disk-brake cooling duct for NASCAR using advanced composites. Designed various types of cab protectors for semi-trailers, parts manipulation system for brake pad production conveyor, production press for assembly of motor into housing. Designed mounting for all structural items included in McDonnel Douglas 600N Electronic News Gathering System for NBC TV’s national use. Responsible for computer cabling, Internet, intranet, PC setup, maintenance & debug. Also maintained twenty-four port Samsung DCS phone system & wiring.

Piney Flats, Tennessee, United States

Bell Helicopter Model 212 Related Project: Wrote high skid gear drop test plan & conducted drop test. Incorporated test data in structural Substantiation. Completed Parts & Installation Conformity of supporting structural modification kit for Hoist System.Bell Helicopter Model 407 Related Projects: Designed & substantiated Passenger Sliding Door. Modified current design of Folding Maintenance Step onto composite skin. Completed structural analysis & testing.Bell Helicopter Model OH-58 Related Projects: Worked with U.S. Army to adapt existing long-range fuel system for civilian Bell Model 206L helicopter to military OH-58 version.Engine Related Projects: Redesigned valving kit for C20, B17, C30, C28, T5311, C30R & LTS101 series turbine engines to simplify compressor washes. Required thorough understanding of sealing devises & thermal expansion.General Projects: Managed up to twenty shop employees during development, testing & prototype of new designs.  Completed design of self-latching cargo hook, tested design for integrity & endurance, & assisted production. Incorporated self-latching cargo hook into existing design for multiple hook mounting. Designed replacement/custom interiors & windows for numerous models of Bell, McDonnell Douglas, Agusta & Aerospatiale Helicopters using vacuum formed plastics. Responsible for technical support to customers with verbal & written response. Wrote & updated process specifications & installation instruction manuals for manufactured parts & assemblies.

Bristol, Virginia, United States

 Lead company to most profitable year by planning layout, moving, reassembling machinery & tooling; in addition, supervised & assisted with production of 60,000 worm gears with multi-stage manufacturing processes for Electrolux. Developed & managed Quality Control Department & procedures & SPC studies for customers. Designed cutting tools, cutting tool fixtures, punch & die assemblies, injection molds, serrated gears & spline gears for companies such as Dana Corp. & TRW. Set up, operated & maintained Agie Wire & Sinker EDM to cut complex geometry in three axis with moving heads. Wrote programs for a Starrett CMM to produce SPC reports on complex motor housings for Bristol Compressors.