Robert Merlo

Robert Merlo Email and Phone Number

Supplier Development Engineer at Caterpillar Inc @ Caterpillar Inc.
deerfield, illinois, united states
About Robert Merlo

Mechanical Engineer with diverse work experience and background in World Class construction and mining equipment and diesel engines including transmissions, engine cooling, heat exchangers, cooling modules, fluid conveyance tubes, battery modules, brazing, welding, castings, stampings, tube bending, tube end forming and more. Self-motivated, driven, hard working with strong background and experience in project management, supplier development, collaboration, design for manufacture and APQP (Advance Program Quality Planning). Demonstrated ability in analysis, problem solving and execution. Recognized as a team player and leader, skilled in working with cross-functional teams for production launches in US, China, Europe, Mexico, Brazil and Japan.

Robert Merlo's Current Company Details
Caterpillar Inc.

Caterpillar Inc.

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Supplier Development Engineer at Caterpillar Inc
deerfield, illinois, united states
Website:
caterpillar.com
Employees:
50927
Robert Merlo Work Experience Details
  • Caterpillar Inc.
    Supplier Development Engineer
    Caterpillar Inc. Oct 2007 - Present
    Mossville, Il
    Supplier Development Engineer, Mossville, IL (2008 – present)Responsible for and worked directly with heat transfer suppliers 2008-2020, fluid conveyance tube suppliers 2020 – March 2022 and battery modules and packs April 2022 - present to ensure that robust process controls are in place to prevent nonconforming product. This includes the continuous monitoring of the supplier’s key processes and quality management systems for improvement opportunities. Managed supplier collaboration and APQP process to ensure production readiness for NPI (new product introduction) programs. These programs include development and production launch of suppliers including, industry leading companies for EGR coolers, cooling modules, radiators, charge air coolers, AC condensers, hydraulic oil coolers and fluid conveyance tubes, tube assemblies and battery modules.• Establish process validation plans to prove out and demonstrate process capability• Organize and lead diverse teams of engineering, manufacturing, purchasing, quality and logistics• Audit process control implementation and effectiveness• Multiple onsite visits to supplier’s plants for assessment, collaboration and to provide technical expertise and proactive planning, including plants in China, Europe, Mexico and Brazil• Ensure PPAP completion and approval prior to delivery • Facilitate successful production launches with no recordable defects meeting quality expectations• Managed numerous plant closures and transfers with focus on risk mitigation• Skilled in 8D discipline, root cause corrective action, PFMEA and control plans• Executed action plans that resulted in sustainable quality and shipping performance improvements
  • Caterpillar Inc.
    Senior Design Engineer
    Caterpillar Inc. Jun 2003 - Sep 2007
    Mossville, Il
    Embedded 6 Sigma black belt within LPSD (Large Power System Division) for Cat Cooling Systems with responsibility for engine mounted heat exchangers and thermostats for engine applications. Established cooling component technical specifications, supplier selection criteria, cost targets, reliability & durability requirements. Responsibilities included managing / creating component development plans encompassing all key APQP activities. Provided technical leadership for field problem resolution, failure analysis, component maintenance, production support, cost reduction and new technology evaluation.• Development, validation and production launch of high efficiency brazed plate type engine oil coolers and high flow thermostat for 2007 on-highway truck engine program. • Championed redesign of 2007 on-highway 525 hp truck engine oil filter base for improved design to reduce complexity and cost. Developed and successfully launched into production within 6 months. Redesign eliminated several known failure modes and reduced cost.• Led project for thermostat family resourcing for consolidation of part numbers, cost savings and improved quality and reliability. Partnered with an established supplier to provide entire thermostat line as drop in replacement. Project was successfully implemented with seamless transition and no disruptions to production.
  • Caterpillar Inc.
    Design Engineer
    Caterpillar Inc. May 2000 - May 2003
    East Peoria, Il
    Design Engineer, East Peoria, IL (2000 - 2003)Transmission design and maintenance for Transmission Business Unit with responsibility for supporting current production transmissions used with (115-145 HP) track type tractors and for (300 to 475 HP) wheel loaders. Responsibilities included design and management of input transmission with forward and reverse for 2750 hp locomotive.• Determined failure mode and root cause of 145 HP track type tractor transmission input shaft failures. Validated improvements and collaborated with manufacturing to release improved design ahead of schedule.• Managed and designed input transmission with forward and reverse for 2750 hp locomotive. Designed rotating clutches employing face valve to minimize parasitic losses and improve shift response time. Performed bearing, shaft and gear analysis. Completed design and ordered prototype parts for prototype build within 1 year as set by project schedule dates• Evaluated field failures of 475 hp wheel loader planetary transmission failures within No. 6 clutch. Compared to similar transmissions, made analysis including flow calculations and determined root cause to be restriction in flow. Increased and redirected flow with addition of new line to provide adequate lubrication.
  • Advanced Cad/Cam Services (Accs)
    Designer/Solid Modeler Alternating In-House And On-Site Positions
    Advanced Cad/Cam Services (Accs) May 1997 - May 2000
    Peoria, Il
    Responsibilities included for designing and creating solid models using Pro-E specializing in castings. Job was held while attending classes full time at Bradley University starting fall of 1998.• Produced solid models to create pattern equipment for castings and FEA studies. • Worked closely with pattern shop and foundries in creating design for manufacturability with a robust model that lent itself to design changes.• Pioneered use of surfacing within Pro-E to create body cores and exterior styling for flexibility and robustness.
  • Cdi Corporation
    Draftsman On Site At Caterpillar Inc.
    Cdi Corporation Sep 1989 - May 1997
    East Peoria, Il
    Responsibilities included computer detailing and maintenance of drawings. Specialized in creating prints of large complex castings and creation of check layouts for verification.• Established and applied geometric dimensioning and tolerancing• Performed tolerance stack up studies• Highly integrated design and prints of transmission and torque converters

Robert Merlo Skills

Six Sigma Apqp Fmea Lean Manufacturing Product Development Manufacturing Engineering Process Engineering Dmaic Heat Exchangers Pro Engineer Project Planning Failure Analysis Program Management Heat Transfer Continuous Improvement Engineering Manufacturing

Robert Merlo Education Details

Frequently Asked Questions about Robert Merlo

What company does Robert Merlo work for?

Robert Merlo works for Caterpillar Inc.

What is Robert Merlo's role at the current company?

Robert Merlo's current role is Supplier Development Engineer at Caterpillar Inc.

What is Robert Merlo's email address?

Robert Merlo's email address is me****@****ail.com

What is Robert Merlo's direct phone number?

Robert Merlo's direct phone number is +130963*****

What schools did Robert Merlo attend?

Robert Merlo attended Bradley University, Illinois Central College, Bradley University.

What are some of Robert Merlo's interests?

Robert Merlo has interest in Boating, Cooking, Exercise, Electronics, Outdoors, Sweepstakes, Home Improvement, Reading, Crafts, Gourmet Cooking.

What skills is Robert Merlo known for?

Robert Merlo has skills like Six Sigma, Apqp, Fmea, Lean Manufacturing, Product Development, Manufacturing Engineering, Process Engineering, Dmaic, Heat Exchangers, Pro Engineer, Project Planning, Failure Analysis.

Who are Robert Merlo's colleagues?

Robert Merlo's colleagues are Cindy Belon, Fernando Hernandez Quirino, Scott & Patty Mcdougall, Brianna Roseman Virgil, Sathish Krish, Ramiro Galindo, Bill Gossett.

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