- Responsible for engine component design including cylinder block, crankshaft, piston, connecting rod, bearing, engine covers, lubrication systems and lubricant, and accessory drive.- Manage a department of up to 55 people.- Led the component launch for the all new 1.5L PFI and GTDI petrol engines, and upgrades to the 2.0L Diesel and 1.0L petrol engines.- Based in the United Kingom but coordinating with engine plant locations in China, India, Mexico, Brazil, and the UK.

- Led product launch issue task forces for crankshaft design, turbocharger design, and exhaust system design.- Led engine related Ford recall actions. Developed vehicle and engine level testing and appropriate countermeasures.- Developed advanced engine technologies including cooled EGR systems for gasoline downsized motors that are compatible with boosted engines.- Directed teams in resolving multiple cross functional launch issues including throttle obstruction, tailpipe smoke, and compressor surge line.- Authored design rules and guidance for engine air path optimization.- Led milestone reviews for turbocharger, exhaust, intake, sealing, fuel injection, ignition, throttle, and EGR subsystems.- Advised FMEA upgrade efforts.

- Responsible for design guidelines and quality documents for exhaust manifolds and turbo chargers globally.- Resolved launch issues for single turbo, bi-turbo, and VNT for gas and Diesel turbochargers- Resolved launch issues for cast, fabricated, and tuned header exhaust manifolds.- Developed new test methodology for thermal mechanical fatigue using field customer correlation data.- Resolved significant field warranty issues.- Invented control strategy for NVH reduction and temperature based fueling.- Wrote Similink model for exhaust gas temperature in a vehicle simulation program.- Wrote Similink model for component wear.

- Used Ricardo Wave and internal codes to model engine behavior.- Matched compressor and turbine to new engine programs.- Developed method for modeling heat transfer for single outlet cylinder head.- Modeled alternate cycles for optimum fuel efficiency.- Optimized engine parameters for performance including cam timing, spark timing, cam profile, compression ratio, and heat transfer.- Developed exhaust header and cam profiles for Baja 1000 competition 6.2L engine.

 Coordinate teams to deliver all new engine programs. Responsible for engine design and program delivery including part geometry and function; target achievement in power, fuel economy, and emissions; minimization of product and manufacturing cost; and optimizing manufacturing strategy and capacity utilization with minimum complexity. Managed external relationships with suppliers and vendors to meet program objectives, cost targets, and deadlines. Optimized label, test, and customer fuel economy using cross departmental analytical techniques. Design durability and performance tests for new cylinder deactivation technology including bench and dynamometer cycles. Applied 1D modeling, Wave, Mandy, and GESIM to predict 6.2L engine performance.

 Completed 9 projects that contributed to significant quality, cost, and process improvements. Collaborated and coached blackbelts from planning, manufacturing, and software. Led a team of cross-companydepartmental activities that eliminated variable cam phaser knocking by implementing a replenishable viscous damper which has avoided millions of dollars in spending. Optimized an industry first open lash adjuster to reduce impulsive noise while remaining high temperature, pump-up, and torque capable.  Developed a statistical sales volume forecasting model to minimize financial risk of missed capacity opportunity cost. Implemented business process redesign to incorporate customer feedback into the engineering improvement process. Analyzed exhaust valve stress for infinite fatigue life.

 Coordinated 4.6L Engine Programs for the 2005 Mustang, 2004 LS, and 2001 to 2002 Town Car. Invented a model, wrote a strategy, and developed a test plan to implement a cross-department initiative for an oil temperature inference. Developed a cross department whole engine cooling model to optimize radiator pressure losses to prevent water pump cavitation. Coordinated Design Verification test plan and design standard compliance through FMEA and robustness documents for engine systems, intake manifold, cam cover, chain drive, VCT, and others.

 Received four patents for combustor design: 6,481,209; 6,497,103; 6,540,162; 6,736,338 Performed Computational Fluid Dynamic analysis and testing of advanced concept high performance jet engine combustion systems on a joint GEAE, DOE, DOD project.

 Conducted numerical and experimental testing of potential techniques for lowering emissions and improving fuel consumption for Diesel engines. Used Ansys to the design high peak pressure cylinder liners. Collected customer duty cycle data and developed a technique for simplified replication.