Ben — Engineer

Research, design, develop, implement, test, and validate products, processes, equipment, and infrastructure in new and existing applications

Plant layouts, elevation views

Conducted door, rear fascia (W166 AK Rear) fit and function studies with modular billet aluminum (“Cubing”) model; data guided Einfuhrung Z3.2 door adjustments and Sylvania tail lamp manufacturing standards. • Used CMM and production data to make body shop adjustments for vehicle fit and function

Automotive body inspection. Compare scan to CAD for root cause analysis and corrective action.

Navigate model to compare parts to CAD during inspection: point measurements, section views.

Research, design, develop, implement, test, and validate products, processes, equipment, and infrastructure in new and existing applications, serving under non-disclosure agreement (NDA). • Designed and prototyped hardware for industrial, PLC controlled machine monitoring system (U.S. Patent Pending). • Designed refractory manufacturing process for multinational corporation with 100+ years of operation, including: reactor specification, raw material conveyance, and process P&ID. • Designed chemically sensitive manufacturing process for multinational aerospace corporation to increase process throughput and reduce process rejects through automating bottlenecks Poka-Yoke methodology.

Improved Class-A, Class-B, and Class-C body surface fit and function during redesigned 2014 Acura MDX startup. • Performed quality root cause analysis; implemented production countermeasures, reducing headlight, fender, hood quality checkpoint failure 50%+. • Analyzed stamping defects with inspection gages, computerized optical measuring tool (ATOS), and GD&T designated design tolerance and datum structure; leveraged data in supplier quality improvement requisitions.

Served as multidiscipline Product Development Engineer in Seattle combined heat and power (CHP) OEM startup company. Also served as Test Engineer, Manufacturing Engineer, Project Engineer, Machinist, and Fabricator. • Invented and developed industrial renewable energy, heat recovery, CHP engine devices (2 U.S. Utility Patents Pending) in Seattle startup, resulting in $7.5M valued intellectual property. • Developed high speed steam engines and inlet valve system using CAD (Solidworks), FEA, heat transfer and thermal analysis, fluid mechanics, engineering mechanics, and proprietary, internally developed Matlab engine simulation to satisfy design criteria. Dynamometer tested engine; data validated power and efficiency +/- 2% of simulation. • Designed, built, instrumented custom 1800 RPM, variable load, steam immersed test stand; evaluated various proprietary ceramic, carbide, and carbon materials, optimizing critical engine component sealing, tribology, and erosion performance; resulted in 12X service life and $80k+ savings versus supplier proposed solutions. • Implemented DFMA, design-to-cost strategies, and developed manufacturing plan for complex engine components, including: pistons and cylinder heads; saved 3+ weeks and $40k+ scrap and rework. • Created conventional and GD&T manufacturing drawings. Manually machined critical engine components from billet aluminum and steel materials. Managed external grinding and CNC machine operations; saved 4+ weeks and $15k+.

Invented and developed industrial fan and pump drive, filling market voids from existing technology limitations. • Invented, designed, and developed Hydrostatic Variable Drive (HVD; U.S. Utility Patent Pending), outperforming Variable Frequency Drives (VFD) in adverse applications, and damper operation in 92% of flow range. • Collected, interpreted electric motor power and fan airflow data (AMCA standards), on HVD, VFD, damper prototype. Revealed 10% increased HVD motor efficiency versus VFD; 74% energy savings versus damper. • Increased steam plant summer thermal efficiency 4% with 1st commercial HVD; 8,000+ hours annual operation.

Served Body, Maintenance, Assembly departments in multiple capacities during redesigned 2011 M-Class startup. • Initiated development of custom "clip" removal tool with Catia data, manual and CNC mill and lathe; improved process safety, reduced cycle time 50%, and saved ~$2500 per "clip" resultant production line stop. • Conducted door, rear fascia (W166 AK Rear) fit and function studies with modular billet aluminum ("Cubing") model; data guided Einfuhrung Z3.2 door adjustments and Sylvania tail lamp manufacturing standards. • Used CMM and production data to make body shop adjustments for vehicle fit and function