Kevin
J. Brault
President
Sharp Technologies and Design Group
kbrault@sharptechdesign.com
http://www.sharptechdesign.com
480-899-5565 |
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2000 to Present:
President,
Sharp Technologies and Design Group, Chandler Arizona
Mechanical Engineering, CAD Administration and
Network Administration Services
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- Successfully managed seven independent, parallel projects and directed the
efforts of six engineers and designers to design and develop
engineering solutions on accelerated schedules for a variety of
customers in the industrial, commercial and aerospace industries.
- Created detailed models and drawings in Pro/Engineer and
SolidWorks.
- Provided Finite Element Analysis using CosmosWorks and
Pro/Mechanica.
- Manage CAD and other data in Pro/Intralink, Windchill,
Teamcenter and Subversion.
- Prepared proposals including costing and scheduling
estimates for various industries.
- Tray and pallet handling and conveying equipment for the
biochip industry.
- Tray, boat and pallet handling, conveying and high speed
pick and place for the semiconductor industry.
- Silicon wafer polishing (CMP), cleaning and handling
equipment.
- Fixturing and automated assembly equipment for the
aerospace and consumer products industries.
- Developed systems software practices and policies to increase
engineering department efficiencies.
- Developed procedures and software systems to organize concurrent
engineering data among engineers all over the world.
- Developed automated document release systems that reduce cost,
error and are ISO standards compliant.
- Setup and maintain network systems (Microsoft Small Business
Server and Linux) that are cost efficient for
small and medium enterprises.
The following are a few of the projects I successfully completed:
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MCAD Administrator, General Dynamics Advanced Information
Systems
Automated steps in the design activity and developed new release and
data control mechanisms to enhance data integrity and reduce cycle and
work time. Improved modeling techniques to create more "intelligent"
models, reducing design and checking effort and errors and preparing the
company for "drawing-less" documentation. Performed Pro/Intralink 3.0 to
3.4 data migrations for two sites. Performed data separation for one
site (department split). Performed Pro/Intralink 3.4 to Windchill 9.1
migration for two sites (Over one million objects, 510 GB of data). |
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Mechanical Engineer, Honeywell Engines, Systems and Services
Brought “Out of the Box” ideas to solve new challenges.
Utilized Pro/Engineer and Pro/Mechanica to expedite the design, reduce
cost and minimize the mass of new control valves for the Airbus A380
aircraft. |
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Senior Analysis Engineer, Titus Cycles
Analysis Engineer Utilized FEA to validate and optimize bicycle frame designs.
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Senior Mechanical/Analysis Engineer, Raytheon Missile Systems
Optimized Missile Fixturing/Lifting Ring for weight and strength using
Pro/Engineer and Pro/Mechanica. Fixture designed to be configurable with
adjustment components uniquely stored on the ring itself..
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Senior Mechanical Engineer, Akrometrix
Portable Moiré Flatness Measurement Machine: Unique sheet metal
enclosure is designed to maximize rigidity and minimize mass. The
designed required a stiff structure which was achieved without heavy
frame members.
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Senior Mechanical/Analysis Engineer, Watts Premier
Potable Liquid Pressure Vessel: Utilized new materials and devised new
manufacturing techniques along with FEA to increase cost
advantages over current product.
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Senior Mechanical/Analysis Engineer, MEMC
Wafer Handler in Wafer Cleaning System: Replaced complicated and
troublesome bulk wafer transfer system with six axis robot and load
port. Analyzed motion with Pro/Mechanism.
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Senior Mechanical Engineer, Motorola
Cell Phone Product Releases:
- Produced solid production models and
drawings from Industrial Engineering surface models.
- Worked with electrical engineers to mechanically package
electronic components.
- Evaluated other designs for technology reuse and improvement.
- Evaluated first
article QC reports, performed accelerated life tests and provided corrective action
recommendations. Worked with Engineers in Florida and China on issue
resolution.
- Reduced Accelerated Life Test cycle time and variability by improving the test process.
- Optimized rigidity by utilizing Pro/Mechanica.
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Lead Project Engineer, Rainbird
Automated Sprinkler Head Assembly Machine: Machine assembled and
inspected six components to produce a finished product every two
seconds.
Managed six engineers and designers to meet schedule and performance
requirements for the $730,000 project. |
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Senior Mechanical Engineer/CAD Administrator, Novellus
CMP equipment for the Semiconductor industry:
- Provided Pro/Engineer and
Pro/Intralink support and training to 28 member staff. Developed
automated document and CAD data release procedure. Simultaneously
supported design efforts on new CPM products.
- Wrote software to analyze license logs and negotiated a 34%
reduction in software product maintenance costs to save the customer
$230,000 annually.
- Provided cost return analysis for hardware upgrades increasing
engineering efficiency.
- Developed Pro/Engineer scripts to automate repetitious
operations reducing modeling time and design errors while
standardizing design and drawing methods.
- Implemented an automated “PDF” process where drawings are
automatically printed to a “PDF” file, watermarked with a “Released”
stamp and pulled into a data access system. Reducing Engineering
work load and providing “Released” documents to the whole
organization within 20 minutes of approval.
- Developed automated process and software to “push” Bill of
Material data from the Pro/Engineer to an MRP system. Eliminated
the need to “Release” a BOM under an ECO. Reducing engineering work
load and updating MRP information in less than 20 minutes. Automated
rollout of new software releases. Reducing Engineering
interruptions.
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Lead Mechanical Engineer, Unaxis
High Speed JEDEC Tray Substrate Pick and Place: The challenge met was to
rapidly load and unload JEDEC trays with new, good and failed devices
with two, four axis SCARA robots while simultaneously staging and
re-ordering non-WIP trays.
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Lead Mechanical Engineer, Sonix
Automatic Ultra-sonic substrate Inspection Machine
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Lead Mechanical Engineer, Unaxis
Sideways JEDEC Tray Handler
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Lead Mechanical Engineer, Motorola
Substrate Singulation machine: Successfully merged two separate
technologies (wafer dicing and JEDEC tray loading) to produce a machine
that replaced two pieces of equipment and reduced cycle time and floor
space.
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Mechanical Engineer, Speedfam
CMP equipment for the Semiconductor industry: worked with supplier in
Israel and customers in Europe to retrofit the CMP tool with inline
inspection systems.
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1997 to 2000
Staff Engineer, Motorola Manufacturing Systems - Phoenix, Arizona
Division of Motorola producing automated manufacturing equipment for the
semi-conductor industry. |
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Reported to the Engineering Manager for the
design, development and project management of automation and BGA
manufacturing equipment projects. Responsible for Pro/ENGINEER (Rev 17 –
2000I) and Pro/PDM (Rev 3.5) software and hardware administration (UNIX
and NT). |
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- Generated engineering concepts through final designs, work with vendors and
customers to bring innovative automated equipment solutions to
semi-conductor manufacturers worldwide.
- Worked with engineering team to bring to market a new substrate
singulation machine generating ~$700,000 per month in sales.
- Developed automatic tool alignment system that reduced machine
setup time by more than 70%.
- Led team to design and develop a manual solder sphere attachment
machine for CBGA scale wafers/substrates that can place 200,000, 0.3
mm diameter spheres in 3 minutes on a 300 mm wafer.
- Orchestrated project team with engineering, customers and
manufacturing to reduce the cost of second generation wafer BGA
machine by 40% and make a mass-marketable product.
- Worked with engineers in other countries to develop
advanced BGA sphere attachment process for $1.2 million order.
- Developed new technologies to reduce production lead time (50%)
and cost (30%-70%) of sphere attach tooling.
- Reduced number of unique parts while increasing performance.
- Redesigned conveyor system and reduced cost by 60% and lead time
by 67%.
- Specified and implemented computer hardware upgrades to reduce
engineering time and administration costs.
- Converted computer platforms from UNIX to NT.
- Worked with four other sites to develop common engineering
practices and software/model libraries.
- Provided Finite Element
Analysis (FEA) of critical components Using Pro/Mechanica.
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1995 to 1996
Project Engineer, Ryobi Outdoor Products - Chandler, Arizona
Lawn and Garden and Power Tool Manufacturer with locations in the United
States, Mexico and Japan. |
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Reported to the Director of Engineering for
the design, development and evaluation of hand-held lawn and garden
products. Utilized Pro/ENGINEER CAD-CAM software (UNIX and NT Operating
Systems) to design new products with common features and parts,
resulting in fewer manufacturing and production changes. |
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- Generated Pro/ENGINEER part models that were "Family Driven",
simplifying and reducing engineering design time on new, similar
components (primarily die-cast and injection molded), and thus,
bringing new products to market faster.
- Evaluated, upgraded and automated data acquisition hardware and
software for emissions equipment resulting in increased accuracy of
data and rapid production test evaluations.
- Performed extensive tolerance studies of several similar
assemblies resulting in design changes that reduced the number of
new components and assemblies and thus reduced inventory and tooling
cost.
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1990 to 1995
Application Engineer - Small Engines, INA Bearing Company, Inc. - Fort
Mill, South Carolina
The world's largest producer of needle roller bearings. |
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Reported to the Application Engineering
Manager for the calculation, design and proposal of roller bearing
arrangements, through development of samples, production start-up, and
customer support including bearing failure analysis and corrective
action proposals. |
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- Worked with Field Sales and Product Engineering on customer
accounts totaling over $15 million, increasing sales by 78% in four
(4) years, and increasing 1994 sales by over $3 million (31%),
exceeding the 25% forecast.
- Generated bearing proposals and Structural FEA's and provided
engineering support to a customer, resulting in acquiring a three million dollar account from a competitor.
- Developed computer engine simulation software to increase the
accuracy of bearing life calculations in conjunction with developing
statistical tolerance standards for connecting rod assemblies.
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1987 to 1990
Project Engineer, Force Outboards (Mercury Marine) - Division of
Brunswick Corp. - Hartford, Wisconsin
A $150 million division producing marine outboard propulsion drives. |
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Reported to the Director of Engineering for
the design, development and introduction of new products and product
improvements on the 5, 9.9, 15 and 25 horsepower outboards. |
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- Designed and developed new porting, piston (Thermal FEA), reed
valve and starting system on 5 HP engine, increasing power output by
30%, reducing RFI emissions, reducing cost by $7 per unit and
increasing life by 200%.
- Developed a Pro/ENGINEER CAD solid model of the 25 HP combustion
chamber and crankshaft, eliminating experimental prototypes and
reducing product development costs and lead times.
- Developed new reed valve assembly on 90 through 150 horsepower
models reducing the number of components by 10%, cost by 17% and
increasing performance by 5% to 8%.
- Implemented Concurrent Engineering with manufacturing engineers
and vendors on the 25 HP project, reducing production costs, capital
costs, tooling lead times and engineering changes.
- Utilized common vendor products and existing in-house fixturing
and assembly stations common with other product lines.
- Generated and maintained Bills of Materials for the 5, 9.9, 15
and new 25 HP model lines and supervised the efforts of up to three
(3) designers and three (3) technicians.
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Education: |
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Bachelor of Science Degree - Mechanical
Engineering - 1987 University of Wisconsin - Madison |
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PTC |
Pro/Engineer Basic and Advanced |
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Professional
Affiliations: |
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Phoenix Pro/Users Group - Chairman |