David Nicholas Email & Phone Number

Chattanooga, Tn, Us

3D Modeling, 3D Scanning, and 3D Printing

United States

A220 FAL Efficiency ProjectObserve A220 FAL WorkbooksAnalyze Data, Propose and Implement SolutionsProposal to Eliminate 13 Hours From FAL Build Accepted by Airbus Proposal to Reduce Airframe Fastener Painting by 50% Accepted by Airbus

Alabama, United States

Multinational Tier 1 Automotive SupplierSenior Project EngineerCAPEX for High Pressure Aluminum Die Casting and Dry Hearth Furnace 2.5 Million Per Year Cost SavingsCasting Machining.SolidWorks - design and detail parts and assembliesCapital ProjectsPlant LayoutMachine FoundationsZeiss GOM Flexible Fixture DesignLocking Coupling for Leak TestRotating Assembly Fixture

Mobile, Alabama, United States

Cylinder & Head Lines Machining & AssemblyInterpret CMM Reports for Cylinders & Cylinder HeadsCNC Programming, Okuma, Mazak, Mori-SeikiCREO Parametric 4 - Design Tools & FixturesAutoCad - Design Tools & Fixtures3D Printing - PRUSANew Valve Leak Test Seal Design - Cost & Quality ImprovementContinuous Improvement InitiativesWeekly Report Out to COO and Staff

Project Engineer – Central EngineeringCVJ Shaft Components - MachiningWrite, Submit & Execute CAPEX Successful ProjectsDesign & Build Eddy Current Inspection Machines In-House - $2.5 million Cost AvoidanceCombustible Dust Collection – Risk Insurer Approved Solution - Template for Division First Engineer in Division to Develop Supplier & Solution for Combustible DustCREO Parametric Design (Pro-E) – 3D Parts, 3D Assemblies & Detail Drawings

Greater Nashville Area

Tool Engineering - (4) Cylinder Head Machining LinesResponsible for Cutting Tool Cost Per UnitDevelop solutions that improve People, Quality, Cost, and Cycle TimeSupport Systems ThinkingImproved Valve Spring Seat Cutting Process - Quality Improvement and Cost SavingsDesigned a 3D Printed Lifter Cup Bore Repair Tool - Scrap Cost Savings

Winston-Salem, Nc

Caterpillar Advanced Components & Systems DivisionLarge Mining Truck Axle Manufacturing Winston-SalemSafety – Lowest Recordable Injury Frequency of 30 Corporate DivisionsGreen Field Plant Start-up ExperienceManaged Over $40 million USD in Capital Projects Caterpillar 6 Sigma Black Belt Certification Developed, Specified and Requested Capital for Investment, and Attained Schedules for Projects Managed, Budgeted, Delivered and Installed EquipmentImplemented New Processes and In-Process VerificationAdvanced Work Holding Designs for Large Ductile Iron CastingsDelivered 1.67Cpk or Better on Part Key Design CharacteristicsSuccessfully Selected for Talent - Hired & Trained Manufacturing EngineersSiemens NX Software PLM – Modeling, Assembly & Drafting of Cutting Tool AssembliesSiemens Teamcenter PLM – Create and Maintain Data Sets for Cutting Tool AssembliesImplemented Continuous Improvement Ideas

Mossville, Il

Engine Paint, After Paint Assembly, Commercial Process PlanningC15 – C18 I-6 Diesel Cylinder Block Machining Process PlanningLed 6 Sigma Projects for all Mossville Engine Complex ManufacturingRecognized for Cold Leak Test Improvements Led multiple teams to $4.5 million plus total cost savings

Mossville, Il

Mossville Engine Center B-BC15 – C18 I-6 Diesel Cylinder Block Machining Process Planning supportEarned high customer satisfaction through CI Card SystemIncreased Engine V-Block Production by 57% - Earned Employee of the Month Head face finish cutter - $241,000 per year cost savings & improved surface finish capability

Detroit, Michigan

Tool Management Supervisor 3.7- V-6 EnginesPromoted to position in less than one yearResponsible for tooling setup, tool life, change control and production line troubleshooting Supervision of 10 skilled trades people Plant manager and staff report on tool cost and cutter grind productivity for all shifts Tool / Process Engineer - 4.7 V-8 EnginesSupported machining and assembly processes for crankshaft and piston machining Implemented over $70,000 in annual tool cost savings on mature crank milling process Reduced scrap by $60,000 in annual savings on mature crank fillet rolling operationImproved crankshaft key cutter tool life from 300 cycles to 47,000 cyclesProject management Tool change managementProblem solving boards

Farmington Hills, Michigan

Automotive fiber and foam acoustic insulatorsMolding, laminating and trimming Purchasing molds, trim tools & check fixturesDeveloped and implemented tooling standards Quick change for 75,000 pound compression molds, water jet & robot end-of-arm toolingQuick change molds, robot end-of-arm, steam lines, electrical – down from 3hrs to 30minDeveloped molded-in attachments that eliminated clips $200,000+ cost savingsSelected for special launch team by Director of Program Management & Plant Mgr.Developed & automated mold release application system using Fanuc robot

Manufacturing Engineer -Tactical Tomahawk & Taurus Cruise Missile EnginesLow volume machining & assembly of small gas turbine enginesLean manufacturing cells grouped by families of partsProcess design and planning with Pro-E ProcessDirected CNC programmers and tool designersPurchase tooling, gages and fixtures

Tool Engineer – Drive Shafts, Spline-yokes, Slip-yokes, Weld-yokes & Bearing CapsTooling & process development for driveline component machining Lean manufacturing & reduction of tooling costsTool testing & redesign of tooling for cost savingsOne of two tool engineers that saved a combined $750,000 Implemented $200,000 per year cost savings re-tipping and re-coating reamersWork holding clamp details - material & heat treat changes $150,000 cost savings

Tool Process Engineer – 3.3 & 3.8 V-6 EnginesProject Engineer – purchase of camshaft machining linesReduction of tooling and operating costsFirst engineer in Chrysler Group to specify linear motors for camshaft profile slides $1,000,000 savings – 1 less cam lobe grinder needed due to shorter cycle timesLiaison between machine tool vendors and maintenanceTool Maker - 3.3 & 3.8 V-6 EnginesMaintenance and trouble shooting of engine manufacturing equipmentTool Room – precision detail manufacturing and modificationMaintenance of cylinder block and camshaft machining lines

Journeyman Tool Maker & Job LeaderCustom manufacturing vendor for automotive and defense industriesHigh precision gages, fixtures, and toolingAutomotive, aerospace & military prototype and small batch runsProcess design and planningImplemented CNC machine integration in manual machine tool environment Generate tool paths, setup and operate manual/CNC machines

Bs, Industrial Technology - Mfg, Cum Laude

Activities and Societies: Dean's List Outstanding Student 4/9/1999 Society of Manufacturing Engineers Certification 1999

Associate’S Degree, Applied Science - Manufacturing Technology

Apprenticeship, Tool & Gage Maker

United States Department of Labor: Bureau of Apprenticeship and Training - Certificate of Completion of Apprenticeship.