Abdul Aulakh
Manchester
Summary
Dynamic Senior Hardware Engineer with extensive experience at BAE Systems, specializing in mechanical design and reliability testing. Demonstrated success in enhancing product performance through innovative structural and thermal analysis, coupled with effective cross-functional collaboration. Proficient in ANSYS and FloEFD, consistently driving successful project outcomes while promoting team development in fast-paced environments.
Overview
10
10
years of professional experience
1
1
Certification
Work History
Senior Hardware Engineer – Product Design Analysis
BAE Systems
Nashua
07.2023 - Current
- Apply expertise in the area of mechanical design, structural analysis and thermal analysis of Electronics Packaging towards design of electronics enclosures and/or CCA’s, for commercial and military aircraft applications. Applications include flight critical controls systems as well as non-flight critical high reliability electronics such as cabin systems.
- Mechanical design, development and selection of hardware components for electrical assemblies utilizing fundamental mechanical engineering principles, theories and techniques.
- Interpret mechanical design requirements, customer specifications, industry and military specifications and ensure that all requirements are realized in the design of the equipment.
- Perform structural and/or thermal analysis of high reliability electronics package enclosures, utilizing analysis tools such as ANSYS and FlowEFD or similar tools.
- Support mechanical design aspects of Circuit Card Assemblies (CCA), and Printed Wiring Boards (PWB) through structural and/or thermal analysis.
- Design to meet environmental and reliability requirements typically encountered on military and commercial aircraft programs.
- Design for producibility and cost efficient design in the production environment.
- Establish and maintain effective relationships with stakeholders/leadership across the functions to achieve the optimal design and manufacture of the equipment.
- Support concept designs in support of proposals on an as-needed basis.
Senior Reliability Lead Engineer
BAE Systems
Nashua
10.2021 - 07.2023
- Developing innovative technical solutions to unusually complex reliability problems that require the regular use of ingenuity and creativity with little to no supervision.
- Execute job responsibilities meeting scope, budget, schedule, quality, safety and security requirement according to engineering process.
- Enhance and maintain Reliability database for ease of PMO communication.
- Review and develop a complete understanding of the Reliability Science BOE, Program management plan, Engineering Management Plan and Systems Engineering Management Plan and released Reliability budgets. Work out any discrepancies or schedule misalignments with program leaders.
- Influence the product design by being an active member of the design team and performing as a technical conscience on the program for reviews.
- Performing internal and external supplier interface to resolve reliability issues. Furthermore, supporting Reliability Test Planning and Execution (Accelerated, Growth, Demonstration).
- Performing reliability analyses as applicable, including: Conducting data and trending analyses, Performing RAM trade-off and Design-for Reliability (DfR) analyses and assess RAM performance, Performing Reliability Predictions and Stress/De-rating analyses, Performing Failure Modes Effects Criticality Analyses (FMECA), Performing Testability Analyses, Design and Developing Built-In Test (BIT).
- Lead failure analysis investigation to determine root cause and corrective action with defendable analysis and verified results.
- Prepare, attend and present data for monthly meetings or applicable team meetings or provide written status reporting to the program team leaders.
- Manage or lead a team of engineer to perform reliability task to best support program operations.
Mechanical Engineer II
BAE Systems
Nashua
09.2020 - 10.2021
- Provide Mechanical Engineering Support to the design, development and selection of basic hardware components utilizing fundamental mechanical engineering principles. Also design packaging modules, mechanisms, or components per design requirements.
- Obtain working knowledge of company standard analysis tools. Perform basic static, dynamic and heat transfer analyses of mechanical structures. Compile data for investigation by senior mechanical engineering personnel.
- Acquire a working knowledge of ES Quality System and the Mechanical Design Process. Acquire up-to-date knowledge of developments in mechanical engineering disciplines.
- Provide Mechanical Engineering support to products in production. Manage material issues, perform root cause assessments of discovered issues. Perform analysis as required to verify validity of proposed solutions.
- Generate and review the technical content of drawings, engineering specifications, reports and other documentation associated with the mechanical design.
- Support Engineering team. Work with the Mechanical engineering team to support various products in the product line.
- Leading/Supporting transition to production of new product.
- Working in partnership with cross teams to ensure reliable and timely deliverables of product for the continuous support of the war fighter effort.
- Support the fabrication and environmental testing of design hardware. Assist in the design and fabrication of prototype hardware. Support the environmental testing of hardware including: vibration, shock, thermal, fatigue and others as required.
Engineer II – Process Engineer
BAE Systems
Nashua
09.2019 - 09.2020
- Provide sustaining engineering, process development and new process implementation for RF Systems factory and CCA through hands-on problem solving, data analyses and application of engineering.
- Develop Six Sigma and lean manufacturing principles to implement changes to improve product flow and product yields. Support the Ramp to Rate incentive.
- Analyze defect data to identify areas to improve yield. Works with others to implement process improvements.
- Perform Preliminary Material Review/Material Review Board (PMR/MRB) for the disposition of discrepant material and determination of root cause/corrective action.
- Define and specifies the requirement for assembly tooling, fixtures, and equipment to support current manufacturing operations and recommends changes for production ramp-ups.
- Support the implementation of new automation assembly equipment including programming, process qualifications and supporting tooling design through the tooling group.
- Conduct Production process verification (PPV) on factory product flow to ensure quality is upheld. Create and assist in FAI formation of the product line. Conduct a thorough overview of the FORM 2 to satisfy the customer requirement.
- Conducted a temporary role of industrial engineer for the factory layout. Redesigned the layout of the factory floor to eliminate wastefulness in production processes.
Mechanical Engineer I
BAE Systems
Nashua
05.2017 - 09.2019
- Support Product Design. Provide Mechanical Engineering support to the design, development and selection of basic hardware components utilizing fundamental mechanical engineering principles, theories, and techniques. Also design and development of specific packaging modules, mechanisms, or components to meet specified design requirements.
- Perform Mechanical Analyses. Obtain working knowledge of company standard analysis tools. Perform basic static, dynamic and heat transfer analyses of mechanical structures. Compile data for investigation by senior mechanical engineering personnel.
- Support Verification/Validation of Design. Support the fabrication and environmental testing of design hardware. Assist in the design and fabrication of prototype hardware. Support the environmental testing of hardware including vibration, shock, thermal, fatigue and others as required.
- Prepare Documentation. Generate and review the technical content of drawings, engineering specifications, reports and other documentation associated with the mechanical design.
- Support Continuous Improvement. Acquire a working knowledge of ES Quality System and the Mechanical Design Process. Acquire up-to-date knowledge of developments in mechanical engineering disciplines.
- Support to Sustainment. Provide Mechanical Engineering support to products in production. Manage material issues, perform root cause assessments of discovered issues. perform analysis as required to verify validity of proposed solutions.
Quality Engineer
CPI Aero
Deer Park
05.2016 - 05.2017
- Development of quality plans, production and technical readiness review.
- Prepare and/or review Delta FAIs and First Article Package for customer approval. Prepare and submit deviation requests for approval using customer portals based on customer requirement.
- Perform trend analysis and support variability reduction utilizing lean manufacturing and other advanced analytical skills such as Statistical Process control.
- Manage the corrective and preventive actions as they relate to specific programs and/or supplier and perform failure analysis.
- Support the maintenance of ISO9001-2008, AS9100C systems and perform internal audits.
- Analysis engineering drawing in correlation with supplier parts and determine the compliancy of the part with customer and engineering requirements.
Education
Masters of Business Administration -
University of Massachusetts (UMass Lowell)
12.2024
Masters of Mechanical Engineering -
The Johns Hopkins University
12.2020
Bachelors of Mechanical Engineering - Aeronautical & CAD Engineering
Vaughn College of Aeronautics & Technology
05.2016
Skills
- PowerBI
- SolidWorks
- CAD Software - ProE CREO, CATIA, Solidworks, SpaceClaim
- Structural & Thermal Analysis Software - ANSYS, FloEFD
- Finite element analysis
- COMSOL
- Multi-Sim
- Matlab
- Photoshop
- Solumina
- VBA excel
- Microsoft Office – Word, Excel, PowerPoint, MS Project,
- POWERBI
- ENOVIA
- Test equipment – Vibration, Altitude & Thermal
- Engineering Drawings
- Stress Machines
- Torsion test machine
- Hardness machine
- Wind tunnel testing
- Wireframe design
- Graphic Designing
- 3D Printer
- AS9100 - FAIR
- SAE standards
- Project management values
- Earned value system
- Mechanical design
- Reliability testing
- Data analysis
- Cross-functional collaboration
- Root cause analysis
- Technical documentation
- Thermal management
- Prototyping
- Report generation
- Testing and design
- Data collection and analysis
- Hardware modeling
- Team development
- Hardware design
- Risk assessment
- Multitasking
- Adaptability
Clearance
Active Secret Clearance
Phone - Number
(917)-436-0984
Personal Information
Citizenship: US Citizen
Certification
- Project Management (PMP) - Febuary 2025 ID#4045484
Timeline
Senior Hardware Engineer – Product Design Analysis
BAE Systems
07.2023 - Current
Senior Reliability Lead Engineer
BAE Systems
10.2021 - 07.2023
Mechanical Engineer II
BAE Systems
09.2020 - 10.2021
Engineer II – Process Engineer
BAE Systems
09.2019 - 09.2020
Mechanical Engineer I
BAE Systems
05.2017 - 09.2019
Quality Engineer
CPI Aero
05.2016 - 05.2017
Masters of Business Administration -
University of Massachusetts (UMass Lowell)
Masters of Mechanical Engineering -
The Johns Hopkins University
Bachelors of Mechanical Engineering - Aeronautical & CAD Engineering
Vaughn College of Aeronautics & Technology