Tom J. Kelly II
Garden Grove, California
Embedded Files
Creative History:
Creative History:
Thales Avionics, Inc., Irvine, CA
Industrial Architect/Procurement Technical Specialist/Principal Industrial Engineer.
8/12 to 12/17
My broad-based engineering & production experiences, as well as supplier-customer balance demonstrated during the prior Sanmina contract with Thales, were recognized as Skills desirable to Thales. I was hired to identify cost savings opportunities.
Identification of cost reduction opportunities (>$200M/5 years), product industrialization, new product introduction, "Should-Cost" and estimating, cost reduction workshops, early identification at bid of cost/quality/yield/delivery issues impacting industrial operations. Reported directly to VP Operations in support of budgeting, analysis, alternatives.
- Worked with suppliers and system architects to design in reduced costs.
- Organized and participated in system architecture optimization workshops to reduce costs.
- Increased competitiveness in many interconnect and semiconductor commodities resulting in significant reduction in costs.
- Identified supplier cost abnormalities.
- Identified reduction in the cost of DC power by as much as 60%. Analyzed patents for opportunities to design around IP limitations.
- Managed system power budgets and costs of power.
- Coordinated with Thales' power supply group in France to identify methods to make their designs price competitive.
- Identified power supply accessories that were priced 300-500% above should-cost.
- Monitored key supplier's quarterly investment calls to determine that they were intentionally holding pricing high to Thales.
- Analyzed supplier bids for errors, effectiveness, opportunities. Tracked pricing/costing trends for suppliers and components.
- Mentored procurement teams regarding technical nuances of commodities, and contract manufacturing.
- Mentored NPI teams regarding contract manufacturing costs and methods of significantly reducing costs.
- Identified supplier contract weaknesses and exploits.
Sanmina Corporation, San Jose, Ca
Project Manager/Field Service & Sales/Customer Technical Manager
8/08 to 8/12
Managed technical/business aspects of multiple EMS accounts, including Thales Avionics, e-Solar. Assisted business development in identifying new and unusual business opportunities. Managed overseas EMS business, development projects (medical/solar/transportation/Aerospace). Directly/indirectly responsible for more than $150M in new business. Managed relationship with production plants in USA, Thailand, India, China. Managed engineering projects with diverse teams located in Chennai, San Jose, Huntsville. Mitigated difficulties with overseas production transfers.
Thales Planar Transformer
One of the first tasks given to me was to find an alternate source for a series of planar transformers used in certain French designed power supplies, that are used in nearly all IFE products. The Thales Corporate management in France insisted that the IFE division in Irvine make as much use of the French resource as possible. When the economy faltered in early 2009, these planar transformers became impossible to procure from Europe, threatening serious damage to 2009 and 2010 revenues for Sanmina and Thales - about half of scheduled systems would be delivered in 2009, none in 2010.
Sanmina's massive supply chain was not able to locate an alternate source. Thales IFE's procurement department felt the course of action was to pressure the French suppliers, that, were then out of business. All effort in Europe was focused on local customers, very little support was provided for off-shore customers. The French engineers would not provide technical support, and clearly stated that these parts were too complex to be manufactured elsewhere.
Realizing that this transformer was a simple 18 layer PCB glued to a COTS magnetic core, it should be easy to reverse engineer. I ferreted out the technical data of the power supplies, performance data for the transformers, and manufacturing stack-up. All was translated to English and I convinced Sanmina to commit engineering resources to re-create the PCB artwork in IPC standards (original design was per an obscure European standard). I significantly improved the process for establishing air gaps between the magnetic cores, and applying adhesives. Parts were manufactured by Sanmina, transformers assembled in our Thailand plant (next to their target power supplies) and placed through a rigorous performance test regime demonstrating the new transformers actually out-performed their European made counterparts.
Parts were delivered in about 9 months, including delays for political issues within Thales. Costs were 1/3 the cost of the European parts, savings were used to payback Sanmina for the NRE and engineering costs.
Thales France ultimately transferred the manufacturing of all their planar transformers to Sanmina Thailand. Sanmina delivered 100% of 2009 orders by EOY.
Thales Server Fiber Optics
Thales' servers provide audio and video service for more that 150 seats. They are small and dense. The 4th generation server utilized fiber-optics for communications. The transceivers selected were unfortunately a screened commercial grade device that was failing both performance and cleanliness standards. They also needed to be soldered into .128 inch thick PCBs which became challenging due to close pin density (actually required pad clipping) and the thermal sinks created by the multiple ground planes utilized to maintain signal integrity.
I took initiative with a local company (Glenair) to create a superior drop-in replacement part for half the price. These included serviceable ferrules and thermally isolated PCB pins that would allow soldering at higher temperatures for IPC compatible solder joints. The new parts saved Thales in costs and Sanmina in yield, rework, and late deliveries.
e-Solar
Sanmina vigorously competed for a $1B contract with e-Solar to provide manufactured components for their concentrated solar generating facilities. The win was based on superior engineering and global footprint. e-Solar wanted "out of the box" thinking for cost reductions, primarily focused on the $1:$11 ratio between operational savings vs initial capital expense.
I proposed a modification to their field of 170,000 heliostats (motorized mirrors) where for every 250 heliostats, one additional heliostat would be utilized substituting a photovoltiac panel for the mirrors. The motors would be used to point the PV panel directly at the sun, vs reflecting sunlight onto a boiler. This would eliminate the operating power requirement for the heliostats, significantly reduce wiring, connectors (all backbone communications eliminated and replaced by radio links), eliminate power and communications distribution boxes, and significantly decrease installation labor costs and plant engineering costs. All the cost trades were worked out and presented to e-Solar.
Others:
- Managed a 25% reduced cost Thales under-seat processor eliminating many obsolescence issues while maintaining software compatibility. Proposed an alternate 50% reduced cost design.
- Managed an obsolescence mitigation for a Thales video tuner board utilizing new silicon digital tuners to replace older "Can" type tuners. An ASIC was used to maintain software compatibility. Significant cost reductions realized with elimination of strategic inventories.
- Launched a program utilizing Sanmina PCB engineers in Chennai India to reverse engineer Thales' French designed power supply PCBs, including upgrading to IPC standards, live schematic capture, BOM refresh.
- Utilized Sanmina engineering resources in Huntsville and Bangkok to identify circuit and layout design flaws in Thales power supplies.
- Assisted Sanmina Sales teams by identifying additional business opportunities with new customers in utilizing Sanmina engineering resources to increase value.
- While seeking new business from HAAS Automation, I realized that the client threw a curve to our sales team by giving them an RFQ for a PCBA that was extremely old. I knew to take the design to Sanmina engineering for a quote to refresh the design, and maintain backward software compatibility. I made the presentation to the client who was expecting an EMS sales pitch with a long list of exceptions/problems, but instead they received a technical breakdown of a design update project with a significant cost reduction, design simplification, performance improvement. External lead-acid batteries and chargers were eliminated. This developed into a large opportunity for Sanmina.
Distinctive Industries, Inc., Commerce, CA
Director of Engineering
3/04 to 4/08
Managed an engineering/production design team for specification and creation innovative advanced technology automotive entertainment systems and accessories, including TFT LCD monitor design, DVD, media switching & routing, and command & control systems. Responsible for new product concepts: mechanical, electronic, packaging, software designs, vendor selection & qualification. Established validation criteria for imported Asian product designs. Supported marketing, sales engineering and customer support systems. Seat cover patterning, headrest design, FMVSS safety testing, quality, & Asian sourcing. employed additive manufacturing techniques for marketing, molding, prototyping needs.
Some interesting technology we developed:
- Centralized modulation for Infra-red headphones with multiple emitters allowing nearly 100% passenger coverage - no dead zones.
- Single remote control operates up to four headrest DVD players, and some in-dash functions. Additional functionality added for after market seat heaters, motorized seats, aftermarket sunroofs, via OSD.
- Adaptable menus incorporate "plug and play" functionality. All functions accessible via OSD menus.
- Security system to limit menu and control access at seats where passengers may be too young.
- Factory head-unit integration - driver can start/stop/pause/eject/forward/reverse any headrest DVD player.
- iPOD/iPhone/XM Radio Interfaces.
- Wide use of balanced audio/video circuits for superior noise immunity and connector simplification.
- CAD driven design models.
- 3D additive manufactured headrest foam molds for prototyping. Off-shore processing of metal production molds.
- First ratcheting headrest to pass FMVSS testing.
- Redesigned foam molding production line for additional flexibility, throughput.
- Trade-show (CES, SEMA) booth design and construction.
Integrated Headrest DVD Player
3D representation of headrest video display
Solidworks model of DVD headrest foam bun.
Integrated Audio/Video/Power controller
Mecis Inc./Kwikut Equipment Inc., Garden Grove, Torrance, CA
Automotive Product Designer
7/99 to 3/04
Created the first integrated automotive video entertainment systems. Designer/coordinator of automotive entertainment systems for aftermarket and OEM applications. Managed projects for Toyota/Lexus Canada, Kia Canada, and "Mobile-TV" brands. Qualified domestic and foreign suppliers. Moderate travel & business experience in Taiwan, Hong Kong, Seoul, various mainland Chinese Cities. Established overseas manufacturing in Taipei. Responsible for technical oversight of company's imported products. Managed multiple overseas suppliers to improve quality and marketability. Experiences with automotive quality packaging, rotational plastic molding, injection molding, robust DVD/VCR designs, TFT Panel circuitry, DC-DC power converters, audio/video switching and routing, sheet metal, vacuum formed plastics.
Interesting Milestones:
- Rapid Turn Application Development: Cars can be measured Monday morning, CAD files transmitted Monday night, fabrication Tuesday for overnight shipping, validate install on Wednesday. We refined this process to create production ready parts first pass on most OEM trips. Parts included sheet metal, trimmed vacuum formed shrouds, customized wiring.
- First FM transmitter developed for in-vehicle audio delivery. First dual-channel FM transmitter/modulator with digital tuning.
- Modular, configure-on-demand, control boxes.
- First "push-up" overhead DVD using ruggedized PC type tray mechanism.
- Industries' thinnest roof-mounted video display.
- Developed business opportunity adapting our install kit development for competitor products.
- First use of digital formatters for TFT panels
- Digital color scanning of vehicle interiors for authentic color matches.
- Some early systems manufactured in Orange County and were competitive with Asian pricing.
- Trade-show (CES, SEMA) booth design and construction.
Overhead DVD Video Player w/shroud.
"Laptop" thin automotive overhead video display.
Modified VCR for automotive power, added internal video switching and remote control integration.
Customizable control modules.
OEM Bracket for Overhead Video Player.
Rotational Molded Center Console (DVD Player mounted in the rear).
Horizon Instruments, Inc., Fullerton, CA
Aerospace Electronics Design Engineer/Business Manager
15 years employment/ownership, continuing consulting
Establishing partner of a firm to design and certify powerplant instrumentation for Part 23 and Part 25 aircraft. Issued over 24 FAA Supplemental Type Certificates (STC), working with local and national FAA personnel. Responsible for product design (TSO) and validation as well as production system approvals (PMA) . Business operations experience, accounting, payroll, taxes, marketing, sales. Managed RTCA DO-160 and DO-178 projects. Electronic circuit designs: microprocessors (including software), sensors, analog-digital conversion, signal processing, power supplies, displays. Aircraft instruments packaging design.
General Aviation engine instruments are inherently inaccurate. They are essentially old automotive mechanical devices, some call them "Steam Gauges". Climate, age, and suitability to the application all cause significant errors - as much as 20%!
P-1000
Derived from a prior diagnostic tool, the P-1000 had competition. Differentiating features were that the P-1000 incorporated two independent tachometers implemented in software, and accurate to 1 RPM. The extreme accuracy enables additional features such as magneto diagnostics, "Mag-Drop" calculation, easy twin engine synchronization, and increased fuel economy. The important distinguishing feature was FAA approval to replace the mechanical tachometer (whereas others could only be added as supplemental).
The P-1000 is the first General Aviation instrument with software certification per DO-178.
Working with local testing laboratories, we designed the P-1000 (per DO-160) to be so EMI/Conducted Radiation robust that it has been demonstrated to operate in EMI environs where other navigation/radio equipment may fail!
- Indirectly indicates magneto health. Easy failure determination.
- Indicates altitude breakdown, points, condenser failures.
- Easy determination of defective ignition switches.
- Highly reliable - instruments installed in 1986 are still functioning.
Model 336 Aircraft Indicators
In 2017, the aerospace industry passed a significant milestone where product certification costs exceeded development costs.
In 1991 we understood this. With a market for powerplant instruments identified to have 18 major indicator types, and several variations of each, the permutations of design, design approvals, production approvals, and installation approvals would bury a fledgling business. The Model 336 Aircraft Indicators were designed as an "Aviation Panel Meter" as an attempt to further simplify and consolidate the development and certification efforts.
This indicator can be interfaced and calibrated to most aircraft sender types without opening the case. This yields a multitude of available applications (RPM, manifold pressure, temperatures pressures, voltage, amperage...) with one FAA Engineering Approval, and easy addition to existing production approvals. Additional indicators can be deployed as minor software changes and installation kits.
In addition to versatility, the indicator's optical construction made it highly visible in most General Aviation instrument panels.
P-1000 Electronic Tachometer
Model 336 Aircraft Indicators
The Model 336 also includes features such as:
- RS232 Communications
- Programmable relay contacts
- Backup power capable
- Broad range of operating voltages
- Programmable on-display warning annunciators
- Numeric and analog displays
- Internal clocks (three modes)
- Internal data logging
Diagnostic Tools
For those airplane mechanics trying to diagnose engine power problems, handheld versions of the P-1000 were created (one private-label version).
Top Fuel Clutch Controller
Top-Fuel Drag Racing is challenged with the ability to transfer extreme amounts of power to the track. Clutches are controlled by an air cylinder with timed bleed rates. This system is highly weather dependent and difficult to establish a reliable aggressive application of power.
We developed a digital (binary) cylinder using a microprocessor to step the clutch to absolute and repeatable positions. After a few training runs, the system was able to significantly improve launch speed.
Bonneville Salt Flats Streamliner Traction Controller
Salt is slippery. Varying degrees of moisture, salt thickness, atmospherics, and track preparation can impede traction. Most higher performance vehicles will require a "push-off" vehicle to start their run. Transmission shifts will also break traction.
A PLC was programmed to monitor front and rear tire slip ratios and modify engine timing to instantaneously change ignition timing, and thus, power. Significant reduction in tire slip was achieved. Goal for the car will be 440MPH or more during the 2018 racing season.
ModBus protocols are used to communicate with a PC or tablet setup application developed with Visual Studio.
The traction controller, dual ignition systems, data logging system were all networked to a single WiFi device for easy communications with the car.
Flashpoint Bonneville Streamliner
Bonneville Salt Flats Streamliner Transmission Shifting
Cockpit workloads at 450MPH can be challenging. Additional functionality was added to the Traction Controller to provide an automatic gear shifting function during the race. Four pairs of pneumatic solenoids were used to pressurize / vent shifting functions based on race sequence, RPM, and clutch position (manual override).
Top Fuel Racing bypass Valve
Fuel delivery to an 8500 HP engine can be tricky. Too lean and you destroy and engine. Too rich and you risk loosing a race. Fuel pressures range from 20 to 200+ PSI delivered from a cam driven pump. Fuel flow does not necessarily track RPM and mixture is highly dependent upon atmospheric conditions.
The valve controller interfaces with the vehicle CAN based sensor network to obtain RPM and pressure from an intake pitot tube to calculate proper fuel delivery via PWM signal to the valve. ModBus protocols are used to communicate with a PC or tablet configuration application developed with Visual Studio.
Drag Racing Practice Tree
Designed and manufactured the first portable drag racing practice tree. Drivers were able to hone their reaction times to the starting tree when not at the track. Different modes provided for different sanctioning and class rules. Dual trees provided to compete against friends/other drivers.
Early Practice Tree
Later Version Practice Tree
Diary Meter
Malfunctioning milking apparatus can result in infected cows and contaminated milk. The Diary meter was conceived by a dairy owner looking to increase and protect yields. I designed and packaged a microprocessor based device to display vacuum performance information in the tubing. A pressure transducer was fitted with a small needle to insert into the vinyl tubing to monitor vacuum at various points in the barn.
"Instant" Action Photos
Two of my daughters were figure skaters. Thus my involvement in various club boards. Fundraising was, of course, a significant part of the job.
Several of us fathers came to the realization that the people making the most money from our competitions were the photographers. This was money that was literally leaving the organization and we endeavored to change this by building our own Actions Photos service and returning all the proceeds to the clubs.
Two of our parents were talented photographers, thus it was left to me to cobble together the processing using a spare server, lots of Ethernet cables, and donated obsolete laptops. We invested $500 in a software package and thought we were ready to go. The intention was to improve the experience as follows:
- We wanted photos to be available immediately after the skater's performance finishes. This because we felt that if we did not capture the sale at that point in time, it would be lost.
- No Pre-Orders - We photographed all skaters. If a skater did particularly well, we had a product to sell them.
- Finished product available at time of order, including smaller prints. No waiting for the mail.
Photographers had laptops containing the event schedules attached to their cameras. A powerpoint remote control was adapted to allow the photographer to easily select the current skater. This selection would result in photos landing in pre-built directory trees in the camera laptops and mirrored in the servers. A signaling system was developed to inform the servers that a skater was finished. A wired gigabit network was utilized with dual network interfaces in the servers to optimize traffic. AutoHotKey was used to script the photographer GUI.
The purchased software was not able to cope with the volume of photos. A substitute backend process was scripted using high performance photo manipulation tools. Thus, we were able to copy, backup, correct rotation, create thumbnails and lower resolution versions for the sales front-end. Once working properly, we could process 150-350 photos simultaneously from up to four cameras shooting 5MP JPG files. One to six concurrent threads could be supported by the 8-Core processor. ImageMagik was used for photo processing.
We had been to many National, International and local events and have never seen a system perform this way, and this well. In most cases, pre-orders had to be organized, long lines for viewing terminals were suffered (we ultimately had WiFi set up for personal phone and tablet viewing), and you almost always needed to have the finished product shipped to you.
Other Projects:
Other Projects:
- JTAG Scanner.
- USAF refueling boom audio coupling device.
- "Ease-E-Set" Punch Press optical guard efficiency device.
- Holter Recorder - Software and electronic design for highly efficient pre-digital (used cassette tape) heart ECG recording.
- Electro-Mechanical Technology - an early pioneer in the EMS business was co-located with Horizon Instruments, Inc. and owned by my partner. Early surface mount adopter, some turnkey work. I performed a lot of the quoting, bookkeeping, process development.
- JDS Microprocessing - Designed and micro-coded IBM channel adapters used for attaching low cost "dumb terminals" to IBM mainframes.
- Trade-Shows - 10+ years of SEMA and CES, plus a dozen others (automotive, aerospace, general aviation). Booth design, construction, logistics, product placement.
Other Activities:
Other Activities:
- Crew member for the Flashpoint Streamliner. In addition to traction and transmission control designs, I am responsible for the ignition controllers, vehicle wiring, and telemetry, including over 70 sensors.
- Board member Glacier Falls Figure Skating Club - 300 Member Figure Skating Club. Also Webmaster duties.
- Board President Anaheim Amateur Figure Skating Association - Finance and managed an internationally competitive (Team-USA) figure skating team.
- Patent owner/inventor for accurate software tachometer.
- Boy Scout / Cub Scout Leader.
Skills, Experiences, Tools:
Skills, Experiences, Tools:
Skills/ Experiences:
- Product Realization Concepts, Marketing Needs, Economic Design, Business needs
- Distil Overall Program Concepts
- Design/cost trades, Cost engineering/value engineering.
- Styling & Artistic Rendering for Customer
- Customer Presentation & Sales
- Packaging Concepts
- CAD Design (Solidworks, Spaceclaim)
- Electronic Circuit Design
- PCB Layout and Manufacturing Design
- DFM/DFT
- Software Design & Coding
- Part/Component Sourcing & Costing
- Vendor Selection and Qualification
- FAA Engineering Approvals
- FAA Production Approvals
- FAA Type Approvals
- Certification Test Plans
- Configuration Control
- Domestic and International Production
- General Business Management
- AR/AP/GL, Payroll, Taxes, Budgeting
- Marketing/Advertising
- Quality Assurance
- Department Management
- Production/Test/Fixtures
- Travel
- Additive Manufacturing
- Technical Writing / Manuals
- Fiber-optics
- Metals:
- Sheet Metal
- Extrusions
- Machined Parts
- Metal Injection Molding
- Plastics
- Injection molding
- Rotational molding
- Vacuum forming
- CAN Bus / J1939
- Mod Bus
- Ladder Programming
Tools:
- Solidworks, Spaceclaim
- Microsoft Office Tools
- MS Access
- MS Project
- WordPerfect
- Paradox Database Manager
- Quickbooks Pro
- SAP
- Autocad (Draftsight)
- Tango PCB
- Eagle PCB
- Various Assemblers, Linkage Editors
- CodeWarrior Suite
- Visual Basic 6.0
- Visual Studio 10
- Visual Basic for Applications (Excel Macro Automation)
- Z-Corp Modeling Machine
- Price Systems "True Planning" cost estimating system
- McKinsey "CleanSheet" software
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