Senior Mechanical Design Engineer
Current-Led DFx project to design sheet metal bracket. Engaged supplier to optimize design. Created low-cost prototypes for initial fit/function checks. Worked with multi-functional engineering team to develop testing. Performed fit, function, and vibration tests of production representative hardware to validate design. Documented results, presented to team/customer for approval of change, and released engineering package.-Designed missile tailfin. Created Design Requirements Sheet to compile all allocated and derived requirements (performance specs, quality, cost, time, etc.) and worked with analysts to prove design demonstrated sufficient margin, and prepared mechanical models and drawings for release. -Supported production operations team by investigating change requests, consulting with the appropriate disciplines, and modifying date package in PDM database when necessary.-Supported suppliers by attending weekly calls, investigating change requests to help improve yield, lower cost/decrease rework, help scrutinize nonconformances (NC) to determine root cause/corrective action to decrease/eliminate NCs, and attend onsite supplier audits to process witness and ensure that parts are being made to requirements.-Led cross discipline effort to improve yield for problematic composite window assembly. Used 3D scanner to compare hardware to CAD model. Ran design of experiments to give supplier data to improve their process. Through efforts developed by the Production Operations team and supplier, first pass yield was increased from 58% to 82% within 6 months.-Led efforts in manufacturing rotation to bring in new business to site. Visited then current build site, witnessed process, converted specs into manufacturing process plans, ordered all necessary tools and deliverable materials, developed training aids, trained new operators, manufacturing engineers and quality engineers in process, and completed first builds to receive approval to continue work moving forward.
