Lucas Walker

Developed acquisition system (SCADA) platform for our high-frequency weld lines. iba-AG Logix-Xplorer (Rockwell)

Continual control improvements and sensor integrations to prevent process from operating outside of statistically verified limits to maintain tube weld integrity. Brought our defect rate down from 12% to 1% in 2.5 years based on customer facility metrics (condenser coil helium testing Pass/Fail limits due to tube)

Integral part of converting Carrier from copper residential units to aluminum by turning our facility from an experimental program to a reliable internal supplier.

Numerous tooling and machine modifications for process improvements based on root cause analysis of customer complaints or to help with the reliability of downstream assembly.

Developed CMM measurement routines for New Product Development.

Performed customer requested 8D's (automotive), initial PPAP's and annual PPAP's as requested.

Saved a $3.5 million annual LTA for the nacelle strut pre-form of the Boeing Max program.

Designed numerous carbide cold draw dies (Solidworks & some DEFORM) and heat treatment plans for new programs for varying product alloys including A286, M400, Inconel 718, 300/400 series stainless steels and mild carbons)

Wrote numerous CMM measurement routines for product validation / quality validation (Hexagon equipment)

Developed inspection plans and process routes for numerous customers during Covid due to a market dip in our legacy programs to keep us profitable. (transitioned press utilization from titanium products and aerospace to commercial and construction industry applications).

Intimately involved in the renewal of a decades-old F15 products from Ti662 for a renewed defense retrofit contract for Boeing Defense Systems.

Compiled contractual test sheets and Individual Product Specifications for new product development for Airbus with regards to metallurgical and MET testing validation with multiple negotiated revisions and technical reviews from Germany / France.

Assisted as needed with CAM setup issues / troubleshooting for our machined products (we used Esprit)

Numerous process improvement initiates to our equipment, tooling, die shop patterns, process, etc...

Production operator in solid forming department for 2 years

Transitioned to direct support role.

Maintained, modified and improved our forming units for making solid stabilizer bars for the automotive industry.

General maintenance duties as well within the scope of the department.