Mark R. Lytell Email & Phone Number

Sunnyvale, California, US

• Support, mentor and train customers in the use of Ansys Mechanical, LS-DYNA, Motion and Discovery for structural FEA applications.
• Conduct static and dynamic structural and thermal FEA simulations using Ansys Mechanical, LS-DYNA and Ansys Motion for a variety of industries including automotive, aerospace, defense, medical devices, consumer.
• Utilize PyAnsys to automate Ansys Mechanical and Ls-DYNA simulation workflow.
• Train and calibrate DIM-GP models from experimental and simulation data using the Stochos library for Python 3 from Probabilistic Intelligence (https://probaligence.de/stochos/).
• Calibrate PolyUMod FEA material models for use in Ansys Mechanical and LS-DYNA utilizing MCalibration.

Oak Brook, Illinois, US

• Conduct static and dynamic structural and thermal FEA simulations using Ansys Mechanical, LS-DYNA and Ansys Motion.
• Perform electromechanical thermal simulations utilizing Ansys Icepak.
• Establish simulation driven product development as an engineering discipline.
• Train design engineers in performing component and small assembly level FEA simulations.
• Develop and implement corporate simulation strategy with expected reduction in time-to-market by 33% within 3 years.
• Create Python scripts for automation of repetitive tasks in Ansys Mechanical to save 10% in pre-processing time.

Carol Stream, IL, US

• Established simulation-driven design, using ANSYS FEA and CFD software tools throughout design process, by training design engineers to use tools and analyst-level expertise to assess whether results were accurate and.
• Reduced time to first prototype and minimized build/test/fail cycles by training engineers to virtually prototype, using ANSYS FEA and CFD throughout design process.
• Achieved 400% ROI on yearly maintenance cost of ANSYS simulation software by reducing time to market and validation test failures through implementation of simulation-driven design.
• Collaborated with chief innovation officer to spread value of simulation to many Marmon companies.
• Ensured design quality through participation in design reviews, simulation validation and change review board.
• Managed team of materials science, fluids and thermal sciences, and structural engineering subject matter experts whose oversight and team support resulted in higher first pass yield for prototype and validation builds.

Carol Stream, IL, US

• Managed PLM and CAD systems, simulation-driven design, and mechanical engineering consulting as generalist.
• Implemented simulation driven design globally using ANSYS and achieved 500% ROI in the first calendar year.
• Planned and executed programs for implementation of 22 product-related business processes in PTC Windchill PLM, most notably electronic change management and issue tracking, increasing product quality and productivity.
• Developed homegrown business intelligence reports with basic machine learning for data-driven decision-making using data sets from Windchill, reporting metrics and forecasts to senior management.
• Improved Windchill-based processes utilizing Six Sigma methods to reduce non value-added steps.
• Increased engineering productivity by training and driving use of industry best practices, such as 80/20, APQP, Six Sigma, GD&T, top-down and data-driven design, DOE, and reproducible research reporting.

Downers Grove, IL, US

• Collaborated with senior management on the budget, team and strategic direction for R&D projects.
• Secured a Naval sub-contract through Textron by designing the couplings and all metal components for main propulsion and lift fan transmissions in a new Naval hovercraft, using large-deformation, nonlinear ANSYS.
• Expanded gear coupling product portfolio by developing next generation gear coupling family for applications up to 50,000,000 in-lb torque using ANSYS FEA, saving time and cost of validation testing.
• Created analytical model to predict stress in internal hub keyway using response surface modeling of ANSYS parametric design study results, analyzed in JMP.
• Implemented Creo Parametric product design templates and practices to decrease custom design time per Quick Response Manufacturing (QRM) strategy.
• Increased customer value of engineered-to-order products by utilized ANSYS to predict coupling performance as a system element in industrial OEM applications.

Oak Brook, Illinois, US

• Saved over $50,000 by commonizing frames and housing parts in a family of swing gate operators as a Six Sigma green belt project.
• Led mechanical development of 1⁄2 hp AC UL325 medium duty commercial door operator line.
• Supervised and actively participated in modular design of 1⁄2 hp DC swing and slide gate operator from concept to production.
• Worked closely with marketing in establishing requirements for next generation UL325 gate operator line.
• Troubleshot European linear actuator gate operator for successful transfer of production to Nogales, Mexico plant.
• Established best practices for Commercial Products Division (CPD) Mechanical Engineering such as top-down design with Creo, DFMEA, and GD&T.

Mt. Prospect, Illinois, US

• Provided design and manufacturing support for production launch of next generation coin sorting machine (P2)
• Developed solenoid interlock module to prevent users from removing unfilled coin bags in P2
• Designed gear-motor driven automated bag switching mechanism to divert coin flow from one bag to the next when the P2 senses a full coin bag
• Cost-reduced P2 machine components by re-designing or changing their fabrication processes
• Lead cross-functional team in creating specifications for and designing rear-coin access version of P2 machine
• Provided work breakdown structure and manage project schedule/costing for rear-coin access P2 machine

Glendale Heights, Illinois, US

• Invented electronic FCB valve (EV) using linear (stepper motor) actuator technology
• Developed external flavor injector manifold to be used with the EV to inject additional drink flavors on top of the base FCB
• Conducted statistical performance and reliability testing (DFMEA) and tolerance study for electronic FCB valve and flavor injector manifold
• Analyzed flow characteristics of external valve flavor injector manifolds using computational fluid dynamics (CFD)
• Co-authored control algorithm for interaction between EV and flavor manifold
• Filed two provisional patents for EV and flavor manifold design and control scheme

Deerfield, Illinois, US

• Developed structural aluminum castings and electromechanical modular subsystems for Automated Mixing Device (AMD) that processes red blood cells for Pathogen Inactivation (PI), enhancing safety of red blood cells used.
• Employed concurrent engineering precepts such as feasibility analysis, design for manufacture and assembly, and finite element analysis (FEA), utilizing advanced PRO/Engineer techniques and PRO/Mechanica Structure
• Collaborated with Reliability and Quality Engineering (R&QE) employing failure mode effect analysis (FMEA) and advanced product quality planning (APQP) methods during development of AMD Reconstitution Integrated Study.
• Presented at cross-functional design reviews comprising of mechanical engineering, human factors engineering, electrical engineering, software engineering, systems engineering, R&QE, and disposables engineering.
• Designed to and verify RISM fluid ingression and user safety compliance with UL and FDA medical equipment standardsManaged relationship with off-site manufacturing facility in Tampa, FL, and vendors to procure.
• Implemented incremental cost savings, usability, and reliability increases from generation to generation of RISMPerformed overall tolerance analysis on fourth generation RISM

Lavergne, Tennessee, US

• Managed and engineered hand-held random orbital buffer/polisher from concept to production utilizing PRO/Engineer
• Developed adjustable bar clamp/spreader with base and consumer vice that are unique products for a major retailer
• Performed dynamic balance of high-speed rotary systems and stress analysis using PRO/Mechanica Structure and Motion
• Designed plastic injection molded components, sheet metal parts, zinc castings, and powder metal gearing
• Coordinated product specifications, design validation plans, tooling development, and manufacturing efforts with our Shanghai office for industrial vice, consumer buffer/polishers, consumer hand-held power tools, and.
• Administered company wide PRO/Engineer CAD system and PRO/Intralink database

• Designed and analyzed transfer mechanism for automatic transfer switches (ATS) using PRO/Engineer and PRO/Mechanica Motion
• Created theoretical model for motion and feasibility analysis of delayed transition transfer switch (DTTS) concept transfer mechanism
• Conducted experiments and analyzed results to verify DTTS transfer mechanism concept
• Developed quick make quick brake mechanism for new bypass transfer switch (BTS), DTTS, and upgrade for manual operation of the current production ATS

Master Of Science (Ms), Applied Mathematics

Master Of Science (Ms), Mechanical Engineering

Bachelor Of Science (Bs), Mechanical Engineering