Thomas Kos Email & Phone Number

Auburn Hills, Michigan, US

• Engineering lead on customer interface, development, validation and launch of 10 speed transmission shifting systems for medium/heavy truck platform(s)
• Manage test/validation laboratory – responsible for lab staff and the development, procurement and maintenance of new/existing test equipment.
• Technical lead on supplier collaboration - material/process optimization (predictive SPC modeling), cost reduction.
• Manage all ongoing simulation (CAE) and development of new simulation tools.
• Developed predictive statistical tomographic analysis/simulation tool for validation of aluminum die cast components.
• Engineering lead on all BOM / cost model development for new projects – ROI / DOI optimization.

Irving, Texas, US

• Project lead on the design, development, fabrication and implementation of mobile hydraulic sealing endurance test rig.
• Engineering team lead for worldwide design and development of suspension, steering and body articulation systems on all large mining trucks (130 through 400 ton payload).
• Lead material cost reduction projects incorporating procurement, fabrication and final assembly optimization in alignment with developed cost model(s).
• Technical/project manager for the design, development, installation, commissioning and integration of dynamic suspension test rig (world’s largest). Multiple patent applications submitted.
• Technical project team lead on the development and implementation of new hydraulic interface coating providing for increased mobile hydraulic system reliability and durability.
• Developed virtual suspension simulation model. This model provided for a correlated replication of 90(+)% of on-machine loading.

Woodridge, IL, US

• Involved in all phases of development and implementation, component through system design, prototype, structural simulation, test and vehicle implementation. Jointly responsible for financial model optimization and.
• Managed launch of a vocational heavy duty, 70K +lbs. payload truck suspension system in the heavy duty truck market. Currently in production release in Chinese vocational truck market.

Auburn Hills, Michigan, US

• Managed all computational modeling and simulation (FEA/CFD) for the Frankfort facility.
• Handled client interface for new designs and launching platforms.
• Jointly responsible for financial model optimization (ROI and DOI) and completion for newly quoted business.
• Project managed the launch of automotive transmission shifting systems (hydraulic, mechanical and frictional) incorporating initial design, simulation, and prototype testing and final production launch.
• Patent awarded for torque converter shifting system design (U.S. Patent No. 7,357,233).

Auburn Hills, Michigan, US

• Successfully lead failure mode analysis on field returns incorporating transient hydraulic shift scheduling events including cavitations, convergent and divergent flow modeling.
• Directed the timely product and manufacturing transfer of multiple product lines from a different facility to the Frankfort facility.
• Interfaced with international project teams for launch of shifting systems for European and Asian automotive customers. All shifting systems now in production.
• Led teams that optimized manufacturing processes that included insert molding, blanking, forming, friction material bonding and surface refinement, automated inspection and assembly of automotive transmission shifting.
• Conducted extensive statistical process optimization studies that improved process and product capability.

Lisle, IL, US

• Interfaced with client for design presentation, optimization and implementation.
• Lead engineer for the development of a complete high speed electro-mechanical interconnect system for a leader in the Personal Data Assistant industry – Patent granted: (U.S. Patent No. 6,398,577).
• Conducted advanced material research of metal oxide deposition and conduction methods for LCD subsystems. Provided for an optimized material implementation on production LCD displays.
• Designed and conducted advanced thermal, structural, and contact finite element analysis on both subcomponent and final assemblies.
• Optimized FEA solver code (ABAQUS) to conduct specialized simulations.
• Directed research into the optimization of material selection (insert molding, casting and stamping) for high volume electro-mechanical assemblies.

La Grange, IL, US

• Product engineer of high resolution, high-speed optical encoder product line. Involved in all phases of research and development of prototype optical encoders for automotive, medical, and industrial control markets.
• Selected for interface with client for design presentation as well as field failure resolution through FEA simulation.
• Directed research into the optimization of material selection (insert molding, casting and stamping) for high volume optical component assemblies.
• Optimized LED and optical detector coupling method as well as die selection through extensive design of experiments (DOE).
• Involved in the development of ‘in-house’ die and wire bonding processes.

Education record

Education record