Critical Service Issues Resolution. When failures occur with Husky’s machines in the field, I oversee the engineering failure investigation. I coordinate the technical teams during the service response to quantify failure modes using the 8D approach and provide cost effective design solutions that satisfy our customers’ production quotas and schedules.Global Support with Expansive Engineering Scope. Husky’s machines are complex electro-mechanical and thermo-mechanical systems, each one uniquely customized to customers’ specifications. I exercise critical engineering judgment over a wide range of subsystems used globally in commercial consumables, healthcare, and military applicationsInnovative Solutions to Systemic Problems. Once system issues are discovered and identified, I design immediate containment and permanent solutions to resolve them. I support all designs from concept to engineering release for production. Due to the expansive scope, my designs are used not only on Husky’s machines at the customer but also in Husky’s manufacturing line. Examples include an electron-beam welding fixture and power cables design for continuous flex motion.

Design for Manufacturability. Primarily working remotely, I re-design clients existing productportfolio for mass production. Projects include work on extrusions, polymer injection molds, andductile iron castings that are in use in Carports, and other solutions today. I completedevelopment tasks as needed including 3D modeling, engineering analysis, GD&T Drawings,leading design reviews, and working with component manufacturers.New Product Optimization. To the client’s specifications and I generate unique physical modelsthat optimize mechanical components for reliability and cost. I utilize modern engineeringmodeling techniques integrating FEA analysis, physical testing and computational modelingscience in languages including Python, C and HTML.Product Validation and Quality Control. I locate defective components and processes andsupport the integration of the solution. This includes auditing manufactures control processesand designing check fixtures to be used in production. I also design, manage, and document in-house test programs (long term cyclic, impact, static load, corrosion, etc.). I design testapparatus and fixtures.Documented Bankability. All engineering work is to code. For my primarily solar clients: ASCE-07, UL 2703 AGMA, ASME, among others apply. I navigate professional communication channelsto ensure compliance and address engineering issues as they occur. I review and approvedrawings and documents as part of engineering’s release to production. This includes supportingEngineering Change Orders (ECOs) or level 3 Production Part Approval Processes (PPAPs)

Mechanical Design and Development: New Products. For on-time market launch and project delivery, I design and support reliable, low cost mechanical solutions for SunPower’s solar products. As a core member of the Oasis 3.0 Solar Tracker team, I design structural components for 1 GW in ‘17 of renewable utility scale solar trackers at -60% cost. Manufacturability. I design parts and tooling for high volume manufacturing processes. I design production parts for iron castings, progressive steel stamping, UHMW PE extrusions, injection moldings. For a full Product Part Approval Process (PPAP), I review and submit GD&T drawings and approve vendor submissions. We develop relationships with vendors to guarantee high part quality and product compliance. I approve and review FMEA doc, check fixtures, and otherFast Innovation. We utilize simplistic design and local/in-house shop sourcing to produce quick turnaround throughout design cycle iterations. My design team was given SunPower’s “relentless innovation” Prism award for our patent pending designs. Among others, I developed a low profile planetary gearbox, and a high strength structural bearing.

Developed a Successful Startup Product: Working alongside the world record winning P-series solar module team, I worked in a lean startup design unit that designed the structural systems for the Cogenra T-Rex Solar Tracker, the basis for SunPower’s Oasis 3.0 product development. Optimized Mechanical Design: I designed low volume cost structural parts for mechanical subsystems on the solar tracker and created 2D and 3D CAD models for parts and fixtures. I provided GD&T drawings and validated parts. Engineering analysis was done frequently to optimize and produce the required functionality. Active Engineering Support: I would develop usable quick solutions to keep the schedule and costs low, often working with construction crews or manufacturers to improve ergonomics and productivity. I Incorporated customer feedback and requirements into new mechanical solutions.

I turned a $75,000 sunk cost into a working asset. I systematically repaired leaks in a SSIM II to G2101-i Analyzer interface and proved the SSIM II dilutes samples. Due to this discovery I received a 40% pay increase and the SSIM II’s director of new product integration flew to Laramie and provided over $15,000 of free improvements and additional training. I advanced ecological science. I amended an existing failure in an automated IRGA based control system to record critical data by designing a high frequency CO2 capture experiment. I noted that the site’s wind speed exceeded previous published conditions and programmed a CR23X data logger to record wind speed data to address this phenomenon. The data is currently being utilized for modeling and publication.I decreased data analysis time. I programmed R scripts with a leapfrog algorithm to quickly compile the million point data sets from different instruments and time intervals. The R scripts were documented and are of now part of the permanent laboratory library. I repaired lab equipment and trained personnel. I repaired IRGAs to working condition, replacing pumps, fuses, and updating a BASIC data transfer program. I trained lab personnel in the field. I located the cause of a pump failure, reducing repair cost and preserving data.

I reconstructed experiments for safety compliance. After inspection of an experimental setup, I found it unsafe and modified electrical, pneumatic, and hydraulic systems. I documented shutdown procedures, created safety mechanisms and posted hazard signs. My intervention saved the laboratory from costly delays from non-compliance.I improved experiment accuracy. I programmed a MATLAB script to record 1 Hz data and average this data to diurnal plant cycles. Daily updates allowed Dr. Nie to make adjustments that increased accuracy and decreased the time to publication.

I increased visibility of W.E.R.C. with the university community. I wrote a MATLAB program to stream data from an offsite wind tower. It autonomously saved data, updated statistics and modeled power output. I provided capability for users in the university to select the desired information via a touch screen interface.

I analyzed radiation from unique geometries to improve heat transfer. I utilized Monte Carlo probabilistic modeling in conjunction with numerical optimization techniques to locate unique increases in thermal efficiency. Programming was done in MATLAB.

My small team produced a novel exhaust brake below 75% of project budget. It met client specifications to operate for 1,000,000 miles with no maintenance and minimal changes to production cycle. My main responsibilities were modeling compressible flow, thermal gradients and long term corrosion.I built an autonomous test fixture to test unique phenomenon. It actuated a brake to test for cyclic galling while a thermocouple monitored system temperature. The results of the test located a flaw which, when fixed, allowed for successful compliance tests. I produced technical written and oral presentations to clients and supervisors. I garnered valuable experience with collaborative work environments, Tuckman group development, effective scheduling and design reviews.

I decreased the time to verify gas turbine control software. I programmed Autotest scripts, and GAP programs (block based programming) which automatically ran simulations with gas turbine engine control software. I decreased the error rate in gas turbine engine control software by communicating potential problems that occurred during simulation. I recommended potential solutions.

Handled large loads and worked effectively through the night. Was receiving promotion at end of employment.