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.• Patent awarded for torque converter shifting system design (U.S. Patent No. 7,357,233)• Patent awarded for variable race clutch system design (U.S. Patent No. 11,047,434)

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.• Engineering lead on the design, development, testing and production launch of two different steering systems on large surface mining trucks (130 and 170 ton payload).• Engineering lead on the material selection, geometry development and system integration of new alloy suspension bearing design. Patent application submitted.

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 completion for complete suspension system, ROI and DOI optimization.• 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 systems.• 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