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Allen Ramsey's Engineering Career Presentation (Version 7-15-20)

Allen Ramsey
Allen Ramsey

Thank you in advance for taking the time to view my LinkedIn Presentation, which showcases some of my career experiences as an Engineer. It outlines value-add that I have provided as a Mechanical Engineer, Process Engineer and Lead ISO 9001 Internal Auditor.

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Thank you in advance for taking the time to view my LinkedIn Presentation, which showcases some of my career experiences as an Engineer. Please feel free to add me to your professional network on LinkedIn: http://www.linkedin.com/in/allenramsey
Table of Contents (Please click on the hyperlinked slide number) Description 際際滷 Number Mechanical Engineer IBM Fiber-Optic Chip Project 3 Process Engineer Root Cause Analysis (RCA) from a Customer Complaint 6 Mechanical Engineer Roller Failure Root Cause Analysis (RCA) 8 Mechanical Engineer Managing a Belt System Installation at a Mexican Coal Mine 16 Lead Auditor Leading a Successful ISO 9001 Internal Audit 22
Abstract: While working at ACT Microdevices / Haleos as a Mechanical Engineer, I managed the IBM Fiber-Optic Chip Project. I led the project from winning the contract to final production of the chip. This required me to collaborate with suppliers, hire and train operators, design jigs and fixtures, and develop production schedules. The 750 micron stainless steel pins that were inserted inside the chip (See Fig. 1) had to be able to withstand 20 lbs. of pull force per the customers specifications. Each pin had to be tested during the inspection process. The ability to accurately test the pins pull strength was complicated by the silica chip being brittle. I attempted to engineer multiple testing tools that could test the pins without damaging the silica chip. The first pin test jig assembly (Fig. 2) used had about a 20% destructive tendency on the silica chip. This caused cracks that were not usable by the customer and a scrap rate of 20%, which was not acceptable. After much testing and calculations, I designed a pin pull tester with a strain gauge (Fig. 3), which eliminated all of the undesirable cracking while the pin test was performed. This tool reduced scrap by 15% and improved first-pass quality to 95%! Mechanical Engineer IBM Fiber-Optic Chip Project
150 Micron Multi-mode Fiber (Viewed under high magnification) Fig. 1 IB Chip with 440 Stainless Steel Pins Mechanical Engineer IBM Fiber-Optic Chip Project
Fig. 3 Final Pin TesterFig. 2 First Pin Tester Mechanical Engineer IBM Fiber-Optic Chip Project
Process Engineer Root Cause Analysis (RCA) from a Customer Complaint Abstract: While working as a Process Engineer at Celanese Acetate, a customer issued a complaint regarding a bale of product that was exhibiting poor filament distribution and insufficient crimp. This is not desirable to our customer because our product was used in their final product, which could not have visual defects. I led an investigation meeting with all the parties involved. I proceeded to use tools such as the Fishbone Cause and Effect Diagram / 4M Analysis on the next slide to determine the causal factors and root causes. This led to issuing Corrective and Preventative Actions and a revision to the standard operational procedures per the ISO 9001 Standard.
Process Engineer Root Cause Analysis (RCA) from a Customer Complaint
Mechanical Engineer Roller Failure Root Cause Analysis (RCA) Abstract: While working at Bucyrus DBT as a Mechanical Design Engineer, I led a Root Cause Analysis for a customers CEMA D 2.25 x .25 roller failure. The failure occurred at the center point of the middle roller after approximately 130,000,000 cycles of reversed stress. I performed a deep dive RCA with the customer and was provided additional loading information by the customer, which was believed to have caused the roller failure (Potential Root Cause). Point loads of 600# were located at the 23.67 and 47.34 sections of the 71 roller. I proceeded to determine the stresses that were acting on the 2.25 roller using MD Solids. Here is all of the applicable data and calculations for recreating the failure including a copy of the S-N Curve for A-36 steel from Mechanical Engineering Design 5th Ed., which has the endurance / fatigue formulas.
2.25 x .25 CEMA D Roller The 2.25 x .25 roller was believed to have had a 600# point load at 23.67 and 47.34 respectively and this caused the normal stress to be 20 kpsi as calculated by MD Solids (Fig. 1). Based on the S-N Curve (Fig. 2), the 20kpsi is below the Endurance Limit of 29 kpsi for A36 steel. When plotted against the chart with the 20kpsi, it would suggest that the roller should last an indefinite number of stress cycles. I also calculated the expected life using the formulas from the book. This resulted in the expected life for the roller being 79,725,133 cycles or 7.9 x (10^7) cycles. This number does not correspond with the actual life where the rollers are failing, which references as one year of service or 1.3 x (10^7) cycles. Next, it was decided that since the 20kpsi normal stress was too low to cause the failure, the actual forces needed to be determined that are acting on the roller to cause it to fail after 1.3 x (106) cycles. I used the following formula to determine the actual force acting on the roller: Sf = aNb The actual force acting on the 2.25 roller was 29Kpsi. This is very important because this number is also the endurance limit for the steel. If you look at the S-N curve (Fig. 2), this places the roller design right on the knee where afterwards the roller life is exponential. Finally, I used MD Solids to determine that the point forces acting on the roller were approximately 875#. The 875# point forces was the root cause of the 2.25 roller only lasting 1.3 x (10^7) cycles. Mechanical Engineer Roller Failure Root Cause Analysis (RCA)
Roller Failure Analysis Using MS Solids Modeling Fig. 1
Roller Failure Analysis Using MS Solids Modeling Fig. 2
Roller Failure Analysis Using MS Solids Modeling Fig. 3 - 3D Model of Bending Deformation of Roller
Roller Failure Analysis - Shear & Moment Diagrams
Roller Failure Analysis - Slope & Deflection Diagrams The deflection is extremely high considering that the thickness of the pipe is only .250. The 600# loads are definitely the root cause for the failure.
Roller Failure Analysis Calculations
Abstract: While working at Bucyrus DBT as a Mechanical Design Engineer, I managed the installation of a belt system that I helped design. I was onsite at a Mexican coal mine to manage the installation, set up, initial startup and assist in troubleshooting. The layout and prep work at job site are outlined in the pictures on the next two slides. This project required me to utilize my engineering training and my Spanish language skills to communicate effectively with my Mexican customers, the end users of the equipment. This project required me to stay onsite at the Mexican coal mine for a total of a week to managed this installation and startup. I also provided training for how to safely use the newly installed equipment. The final two slides show some calculations that I performed for the system design using a program called Belt Analyst. It is a powerful program that calculates stresses acting on the structure and pulleys based on working load requirements. I created the pulleys models, assemblies and drawings using Pro/Engineer and AutoCAD. Mechanical Engineer Managing a Belt System Installation at a Mexican Coal Mine
Staging roof supports that will be used.Drive system with 500 HP motors Discharge with snub pulley Take-up Mechanical Engineer Managing a Belt System Installation at a Mexican Coal Mine
Inspecting slab for Drive SystemExamining Belt Cleaner Preparing roof support for Discharge Working with my Mexican Counterpart Mechanical Engineer Managing a Belt System Installation at a Mexican Coal Mine
Calculations for Belt System at a Mexican Mine Profile of belt
Calculations for Belt System at a Mexican Mine Pulley and Idler Design
Drawings for Belt System at a Mexican Mine
Lead Auditor Leading a Successful ISO 9001 Internal Audit Abstract: While working at Bucyrus DBT as a Lead Internal Auditor for an internal ISO 9001 audit at one of our manufacturing facilities in Alabama, I was responsible for leading the other members of my team and determining what parts of our Business and Quality Management System was to be audited against the ISO 9001 standard. This required me to coach the other auditors and give them guidance. One way of doing this was by preparing the team well in advance of the actual audit. The Internal Audit Checklist on the next slide is a great tool for preparing for an internal ISO audit. The results of this audit were: 1 Major Finding, 3 Minor Findings and 7 Opportunities for Improvement. Once the investigation was completed, I sent out CAR Corrective Action Reports to the area managers. I was responsible for working with the area managers to determine effective corrective actions and due dates within 30 days of the internal audit. Throughout my career as a Lead Internal ISO Auditor, I have led over 35 audits and participated in over 60 internal and external verification audits to the ISO Standard.
Allen Ramsey's Engineering Career Presentation (Version 7-15-20)

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Allen Ramsey's Engineering Career Presentation (Version 7-15-20)

  • 1. Thank you in advance for taking the time to view my LinkedIn Presentation, which showcases some of my career experiences as an Engineer. Please feel free to add me to your professional network on LinkedIn: http://www.linkedin.com/in/allenramsey
  • 2. Table of Contents (Please click on the hyperlinked slide number) Description 際際滷 Number Mechanical Engineer IBM Fiber-Optic Chip Project 3 Process Engineer Root Cause Analysis (RCA) from a Customer Complaint 6 Mechanical Engineer Roller Failure Root Cause Analysis (RCA) 8 Mechanical Engineer Managing a Belt System Installation at a Mexican Coal Mine 16 Lead Auditor Leading a Successful ISO 9001 Internal Audit 22
  • 3. Abstract: While working at ACT Microdevices / Haleos as a Mechanical Engineer, I managed the IBM Fiber-Optic Chip Project. I led the project from winning the contract to final production of the chip. This required me to collaborate with suppliers, hire and train operators, design jigs and fixtures, and develop production schedules. The 750 micron stainless steel pins that were inserted inside the chip (See Fig. 1) had to be able to withstand 20 lbs. of pull force per the customers specifications. Each pin had to be tested during the inspection process. The ability to accurately test the pins pull strength was complicated by the silica chip being brittle. I attempted to engineer multiple testing tools that could test the pins without damaging the silica chip. The first pin test jig assembly (Fig. 2) used had about a 20% destructive tendency on the silica chip. This caused cracks that were not usable by the customer and a scrap rate of 20%, which was not acceptable. After much testing and calculations, I designed a pin pull tester with a strain gauge (Fig. 3), which eliminated all of the undesirable cracking while the pin test was performed. This tool reduced scrap by 15% and improved first-pass quality to 95%! Mechanical Engineer IBM Fiber-Optic Chip Project
  • 4. 150 Micron Multi-mode Fiber (Viewed under high magnification) Fig. 1 IB Chip with 440 Stainless Steel Pins Mechanical Engineer IBM Fiber-Optic Chip Project
  • 5. Fig. 3 Final Pin TesterFig. 2 First Pin Tester Mechanical Engineer IBM Fiber-Optic Chip Project
  • 6. Process Engineer Root Cause Analysis (RCA) from a Customer Complaint Abstract: While working as a Process Engineer at Celanese Acetate, a customer issued a complaint regarding a bale of product that was exhibiting poor filament distribution and insufficient crimp. This is not desirable to our customer because our product was used in their final product, which could not have visual defects. I led an investigation meeting with all the parties involved. I proceeded to use tools such as the Fishbone Cause and Effect Diagram / 4M Analysis on the next slide to determine the causal factors and root causes. This led to issuing Corrective and Preventative Actions and a revision to the standard operational procedures per the ISO 9001 Standard.
  • 7. Process Engineer Root Cause Analysis (RCA) from a Customer Complaint
  • 8. Mechanical Engineer Roller Failure Root Cause Analysis (RCA) Abstract: While working at Bucyrus DBT as a Mechanical Design Engineer, I led a Root Cause Analysis for a customers CEMA D 2.25 x .25 roller failure. The failure occurred at the center point of the middle roller after approximately 130,000,000 cycles of reversed stress. I performed a deep dive RCA with the customer and was provided additional loading information by the customer, which was believed to have caused the roller failure (Potential Root Cause). Point loads of 600# were located at the 23.67 and 47.34 sections of the 71 roller. I proceeded to determine the stresses that were acting on the 2.25 roller using MD Solids. Here is all of the applicable data and calculations for recreating the failure including a copy of the S-N Curve for A-36 steel from Mechanical Engineering Design 5th Ed., which has the endurance / fatigue formulas.
  • 9. 2.25 x .25 CEMA D Roller The 2.25 x .25 roller was believed to have had a 600# point load at 23.67 and 47.34 respectively and this caused the normal stress to be 20 kpsi as calculated by MD Solids (Fig. 1). Based on the S-N Curve (Fig. 2), the 20kpsi is below the Endurance Limit of 29 kpsi for A36 steel. When plotted against the chart with the 20kpsi, it would suggest that the roller should last an indefinite number of stress cycles. I also calculated the expected life using the formulas from the book. This resulted in the expected life for the roller being 79,725,133 cycles or 7.9 x (10^7) cycles. This number does not correspond with the actual life where the rollers are failing, which references as one year of service or 1.3 x (10^7) cycles. Next, it was decided that since the 20kpsi normal stress was too low to cause the failure, the actual forces needed to be determined that are acting on the roller to cause it to fail after 1.3 x (106) cycles. I used the following formula to determine the actual force acting on the roller: Sf = aNb The actual force acting on the 2.25 roller was 29Kpsi. This is very important because this number is also the endurance limit for the steel. If you look at the S-N curve (Fig. 2), this places the roller design right on the knee where afterwards the roller life is exponential. Finally, I used MD Solids to determine that the point forces acting on the roller were approximately 875#. The 875# point forces was the root cause of the 2.25 roller only lasting 1.3 x (10^7) cycles. Mechanical Engineer Roller Failure Root Cause Analysis (RCA)
  • 10. Roller Failure Analysis Using MS Solids Modeling Fig. 1
  • 11. Roller Failure Analysis Using MS Solids Modeling Fig. 2
  • 12. Roller Failure Analysis Using MS Solids Modeling Fig. 3 - 3D Model of Bending Deformation of Roller
  • 13. Roller Failure Analysis - Shear & Moment Diagrams
  • 14. Roller Failure Analysis - Slope & Deflection Diagrams The deflection is extremely high considering that the thickness of the pipe is only .250. The 600# loads are definitely the root cause for the failure.
  • 15. Roller Failure Analysis Calculations
  • 16. Abstract: While working at Bucyrus DBT as a Mechanical Design Engineer, I managed the installation of a belt system that I helped design. I was onsite at a Mexican coal mine to manage the installation, set up, initial startup and assist in troubleshooting. The layout and prep work at job site are outlined in the pictures on the next two slides. This project required me to utilize my engineering training and my Spanish language skills to communicate effectively with my Mexican customers, the end users of the equipment. This project required me to stay onsite at the Mexican coal mine for a total of a week to managed this installation and startup. I also provided training for how to safely use the newly installed equipment. The final two slides show some calculations that I performed for the system design using a program called Belt Analyst. It is a powerful program that calculates stresses acting on the structure and pulleys based on working load requirements. I created the pulleys models, assemblies and drawings using Pro/Engineer and AutoCAD. Mechanical Engineer Managing a Belt System Installation at a Mexican Coal Mine
  • 17. Staging roof supports that will be used.Drive system with 500 HP motors Discharge with snub pulley Take-up Mechanical Engineer Managing a Belt System Installation at a Mexican Coal Mine
  • 18. Inspecting slab for Drive SystemExamining Belt Cleaner Preparing roof support for Discharge Working with my Mexican Counterpart Mechanical Engineer Managing a Belt System Installation at a Mexican Coal Mine
  • 19. Calculations for Belt System at a Mexican Mine Profile of belt
  • 20. Calculations for Belt System at a Mexican Mine Pulley and Idler Design
  • 21. Drawings for Belt System at a Mexican Mine
  • 22. Lead Auditor Leading a Successful ISO 9001 Internal Audit Abstract: While working at Bucyrus DBT as a Lead Internal Auditor for an internal ISO 9001 audit at one of our manufacturing facilities in Alabama, I was responsible for leading the other members of my team and determining what parts of our Business and Quality Management System was to be audited against the ISO 9001 standard. This required me to coach the other auditors and give them guidance. One way of doing this was by preparing the team well in advance of the actual audit. The Internal Audit Checklist on the next slide is a great tool for preparing for an internal ISO audit. The results of this audit were: 1 Major Finding, 3 Minor Findings and 7 Opportunities for Improvement. Once the investigation was completed, I sent out CAR Corrective Action Reports to the area managers. I was responsible for working with the area managers to determine effective corrective actions and due dates within 30 days of the internal audit. Throughout my career as a Lead Internal ISO Auditor, I have led over 35 audits and participated in over 60 internal and external verification audits to the ISO Standard.