CV Lead Welding Engineer, arc (SMAW, GMAW, GTAW, FCAW, PAW, SAW); resistance (RSW, RPW, RSEW, FW, ADRW)

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CV/Resume ID no.: 88473
Last Updated: Friday, February 13, 2009

SUMMARY:
EXPERIENCED WELDING ENGINEER with theoretical and practical skills in development and application of welding technology for automatic and robotic welding equipment. Strong knowledge/understanding of brazing (TB, IB); arc (SMAW, GMAW, GTAW, FCAW, PAW, SAW); resistance (RSW, RPW, RSEW, FW, ADRW); solid state (CPW, FRW, FSW, MPW); beam (LBW, EBW) welding processes; ferrous (carbon, alloy, stainless steels) and non-ferrous (Al, Cu, Ni alloys) welding metallurgy; NDT methods (VT, UT, RT, MPT) and welding codes. Extensive experience in new projects management and implementation in “hands-on” environment; production floor support; new product development technical welding support, manufacturing & production engineering; lean manufacturing (TPS). Knowledge of Engineering Management concepts.

PROFESSIONAL PROFILE:
Proficient with all aspects of development and application of welding technology for Automatic and Robotic Welding Systems, translating weldment design concept into production process. Experienced with:
• new welding technology R&D;
• recommending and specification welding processes for new product designs;
• design for welding, selecting joint design and preparation, evaluation new weldment manufacturability;
• weldment fatigue failure analysis, weld design problems and field welding issues investigation;
• robots programming and set-up;
• developing, set-up, and optimizing weld parameters and weld process variables, WPS design;
• investigating and troubleshooting production weld process problems;
• weld quality control, selecting NDT methods, destructive weld evaluation (NAMES);
• Robotic Welding Product Assembly line preparation, set-up, and launch;
• functional weld tooling development, robotic fixtures concepts, tooling design (AutoCAD 14, Mechanical Desktop);
• new weld equipment, Robotic Systems, weld consumables, weld tooling specification, justification, procurement, modification, and installation;
• supervising welding technicians and training operating personnel;
• start-up new Plant welding operations and R&D weld analysis Lab;
• TOYOTA world production floor (Just-in-Time, Built-in-Quality, Kaizen, Muda, Pokayoke) engineering support;
• manufacturing engineering at QS-9000 environment (PFMEA, APQP, Gage R&R, SPC, Capability Study, PPAP).

PROFESSIONAL EXPERIENCE:
2003 to HARLEY-DAVIDSON MOTOR COMPANY, Wauwatosa, WI – Motorcycle OEM
Present Staff Welding Engineer of Advanced Manufacturing (Corporate Welding R&D / Global Welding Support Function)
* Research, Development, and Specification of new Braze; Arc, Resistance, Beam, and Solid State welding processes for HARLEY-DAVIDSON and BUELL Motorcycle applications.
* Development and Management of innovative welding R&D programs for various H-D applications (Tandem MIG, Plasma MIG, CMT, ADRW, FSW, FRW, UW, MPW, TB).
* Development of corporate Arc Welding Standard.
* Providing Technical Welding Support to Harley-Davidson (Wauwatosa, WI) and Buell (East Troy, WI) Product Development Centers for all motorcycle product families with welding content:
- H-D Styled Surfaces Systems (Fuel Tanks, Oil Tanks, Fenders);
- H-D Frame Systems (Frames, Swingarms); - H-D Chassis Systems (Wheels, Handlebars);
- H-D Powertrain Systems (Engines); - H-D NVH (Exhaust Systems);
- Buell Frames, Swingarms, Mufflers, Handlebars.
* Providing Technical Welding Support to H-D Motorcycle Assembly Plants (Kansas City, MO and York, PA) and H-D Fab Suppliers – Castalloy (Australia), K-YSK (Japan), Kaiping Gada (China), RPC (Rockford, IL), Center Manufacturing (Byron Center, MI), Preco (Somerset, WI), SWS-Trimac (Saginaw, MI), Norlen (Schofield, WI), Emcon (Dexter, MO), GSK (Taiwan).
* Launch support of XL / Dyna Fuel Tanks Robotic Welding line (LBW, GMAW, GTAW, RSW, IB) at KC.
* Implementation of V-Rod Aluminum Wheel Welding Process (MIG) at Castalloy (Australia).
* Implementation of Buell XB/Ulysses Aluminum Swing Arm Welding Process (MIG) at K-YSK (Japan).
* Design and Weld Development support of Buell 1125R Muffler Welding Line (GMAW) at Kaiping Gada (China).
* Development of Annular RPW for XL Fuel Tank.
* Specification and support of EBW and LBW process development / launch for Big Twin Engine manufacturing.
1999 to HENDRICKSON INTERNATIONAL, Woodridge, IL – Heavy-Duty TRUCKS Suspension Supplier
2003 Senior Mfg. Welding Engineer of Truck Suspension Systems (Corporate Division Welding Function)
* Leading division’s Robotic Welding Development for Heavy Truck Suspension Systems Product lines.
* Start-up and set-up HTruck R&D and Fabrication Plant Robotic Welding operations.
* Providing Technical Welding Support to HTruck R&D Design Engineering Center (Woodridge, IL), HTruck Fabrication Plant (Lebanon, KY), HTruck Fab Vendors – Rose Metal Industries (Cleveland, OH),
Summit Manufacturing and Ottenweller (both Fort Wayne, IN), HTruck Sales in the Field.
* Design, development, and launch of new GMAW Cloos Twin-Wire (Dual and Tandem) processes for Truck
Suspension Systems at HTruck Fabrication Plant (Lebanon, KY) – 5 Robotic (Fanuc) Assembly Lines:
- RT Walking Beam for Sterling, International, PETERBILT, KENWORTH Vocational Trucks – 2 Lines;
- HN Beam and Saddle for MACK, INTERNATIONAL, STERLING, Volvo Vocational Trucks – 1 Line;
- Front Suspension Axle Beam for FREIGHTLINER and VOLVO On-Highway Class 8 Trucks – 2 Lines
(Revolutionary product in Truck industry, forging replacement, absolutely safety critical, 1st time ever welded).
1995 to ARVIN SANGO INC., Madison, IN - TOYOTA Tier 1 Supplier
1999 Production Welding Engineer
* Support welding activity (GMAW, GTAW, RSW, RPW) in production of Exhaust Systems, Instrumental Panel and Door Impact Beam Assemblies for TOYOTA Camry/Solara, Corolla/Prizm, Avalon, Tacoma, Tundra, Sienna.
* Preparation, set-up, and implementation of 6 Robotic Welding new Product Assembly Lines: CAMRY-97 Center Exhaust, COROLLA-98 Front Exhaust and Door Impact Beam, TACOMA-00 Center and Tail Exhaust, TUNDRA-00 Tail Exhaust – 28 Panasonic Robots total (all lines output by 2000-7.4M parts for 2.2M cars).
1986 to WELDING INSTITUTE of RUSSIA, St. Petersburg, Russia - Leading National Industrial Welding Center
1993 Lead Welding Engineer
* Development and Implementation of Arc, Resistance, and Cold Pressure Welding Technology and Equipment.

EDUCATION:
2003 to MILWAUKEE SCHOOL OF ENGINEERING, Milwaukee, WI
2005 M. S. in Engineering Management (Engineering MBA)
1980 to ST. PETERSBURG TECHNICAL UNIVERSITY, St. Petersburg, Russia
1986 M. S. in Welding Engineering (Graduated with Honors)

MS Office, AutoCad

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