Retired

Reliability Engineering and System Safety Engineering

Design new products, reduce existing product manufacturing costs, analyze and remedy product failures, and improve product performance. Perform accelerated life testing using HALT methodologies to estimate the operational life of mechanical components. Conduct fault analysis to isolate returned products and perform statistical analysis to determine failure trends. Evaluate options for incorporating new technologies and manufacturing processes into existing designs to improve performance, decrease costs, and reach a larger market.* Increased operational life by more than 100x, achieving a predicted life of more than 6 million, greatly exceeding the ISO 10325 requirement of 2 million cycles. * Decreased production time by 20 days, reduced costs by 40%, and increased yield by 400% by streamlining parts, conforming design dimensions to tooling capabilities, and eliminating unnecessary manufacturing processes.

• Developed the department process for tracking unit analysis to determine when or if an update or new analysis of a unit is required eliminating repeat work.• Headed a failure analysis investigation that resulted in the creation of additional system checkouts, data recording, and procedure changes.• Design of experiment to determine the optimum cost to test ratio for Environmental Stress Screening, Acceptance Test Screening and Qualification Test Screening.• Design of Experiment to verify results of failure investigation.• Performed a Reliability trade a study and recommended design improvements to the solar array wiring scheme to improve the durability and robustness of the solar array.• Performed Reliability Numerical Analysis, Failure Mode and Effect Analysis (FMEA/FMECA), and stress analyses, on electronic circuits, mechanical units and entire systems to predict performance and verify compliance to requirements.• Coordinated effort with Thermal Engineering, System Engineering, Environmental Engineering, M&P, Mechanical Engineering and others to provide the most accurate reliability analysis to predict field performance.

Worked to maintain the Reliability Program Plan at Lockheed Martin and ensure compliance at subcontractors in order to produce compliant units.Performed FMEAs on units designed and built in-house to identify critical failure modes and methods of mitigation. The FMEA included the risk analysis to assess severity, probability and detectability of each failure mode. Created and maintained the Reliability Growth program for the project to demonstrate the improvements from design changes and the effect on the product performance. Reliability increased from .7 for the 20 mission to .85 during the course of my effort.Design of experiment to determine the optimum cost to test ratio for Environmental Stress Screening, Acceptance Test Screening and Qualification Test Screening.Increased subcontractor yield by 15% and time to delivery by 3 weeks after discovering root cause of the low yield at the supplier. Identified process inconsistencies in subcontractor testing errors that resulted in the low yield. Partnered with the subcontractor to enhance testing and identified areas to improve product yield and performance.Served as a reliability SME on the Management Engineering Review Board. The board included members of each engineering discipline within the program who reviewed changes and assessed impact across engineering areas. As the reliability SME, verified that proposed subcontractor corrective actions and design changes met unit reliability requirements and assessed the impact to the system reliability.Served as the Subject Mater Expert, SME, for reliability during program test plan review cycles to identify test effectiveness, duration, levels and number of units specimen to optimize test results while minimizing cost and time.Participated in supplier Quality System Audits and provided support for supplier system improvements. Reviewed subcontractor documentation, testing methods, and documentation and recommended actions to resolve noncompliance issues.