STEFAN L MELLO
Avondale
Overview
27
27
years of professional experience
Work History
Lead Systems Engineer - RMSS
Honeywell
Tempe, AZ
09.2024 - Current
- Responsible for working with a team of engineers in the design and support of ongoing and new business activities related to Honeywell's Advanced Electromechanical Solutions product lines including flight control actuation systems and environment control systems
- Lead program efforts through the entire life cycle: proposal, design, build, test, and customer on-site support.
- Worked assignments and perform tasks with minimal oversight
- Provided written reports and oral presentations to engineering management and customers to explain tech approaches and project status
- Lead a collaborative work environment of expert design and system engineering teams effectively where our on-time deliverables (97 %) and quality of work has garnered praise from our customers
- Clearance: SECRET
Principal Engineer – Electrical
Northrop Grumman Space Systems/Launch & Missile Defense
Chandler, AZ
11.2019 - 09.2024
- Study design concepts and criteria to ascertain engineering principles involved (Plan, Preparation and Completion of designated designs)
- Evaluate existing completed designs and make modifications necessary to satisfy requirements
- Develop, coordinate and conduct the test programs required to evaluate designs
- Oversee component supplier design, analysis, manufacture and test
- Apply electrical engineering principles to adapt or improve upon heritage features from legacy designs & programs
- Support & lead testing and/or evaluation/validation of electrical components, subsystem, system analytical modeling and actual system implementation
- Perform Root Cause Analysis (RCA), including sneak circuit and bent pin analyses to assist in identifying trends and the evaluation of Risks & Uncertainties
- Telemetry, Data Acquisition, Encoders, Instrumentation and Cable Design on Launch Vehicles (Targets and Deterrents)
- Clearance: SECRET
Sr Systems Engineer – Space Network Ground Segment Sustainment (SGSS)
General Dynamics Mission Systems
Scottsdale, AZ
09.2017 - 08.2019
- Analyzed customer and lower-level requirements, and collaborate with test engineers to develop RMA verification test strategies, plans and procedures
- Reliability, Maintainability, Availability, and System Safety Analyses to include:
- O Failure Reporting and Corrective Action Systems (FRACAS) activities
- O Failure Modes and Effects Analysis (FMEA)
- O Reliability MTBF estimation and justification
- O Availability Analysis modeling
- Executed analyses for affordability, survivability, vulnerability, susceptibility, system security, regulatory certification, and product assurance to ensure mission success
- Clearance: SECRET
Sr Systems Engineer – Engines & Power Generation Systems (Technical Lead)
Honeywell Aerospace
Tucson, AZ
07.2017 - 09.2017
- Lead investigations and resolve issues for production, Integrated Supply Chain (ISC), and customers, field failures, application problems and design related product problems
- Coordinated liaison activities with Honeywell cross-functional teams, suppliers, and customers
- Provided constructive critical feedback to assure a high standard of the work products submitted to customers
- Hardware; assembly and disassembly
- Produced clear, concise, and technically accurate reports to communicate findings, analyses, and technical position statements
- Contractor: Collabera
ILS Systems Engineer 4 – Systems Integration & Verification
The Boeing Company
Oklahoma City, OK
10.2016 - 03.2017
- Lead the development of system level integration testing architecture by identifying unnecessary complexity and risks to integration and test execution.
- Determined design, functional and performance testability criteria, translating and synthesizing Test As You Fly/Operate Philosophy into test programs, leveraging best practices and technology from across the enterprise and/or industry
- Responsible for the daily build and release operations of multiple key products, and communication with development, QA, Tech Support and Product Management
- Developed detailed test procedures, instrumentation and configuration definition; needed to perform testing and minimize risk within the constraints of the test plan - Taking into account System Safety analyses to address hazard mitigation or elimination
- Reviewed test data, including off-nominal event investigations, for accuracy, quality and/or fidelity; prepared and published test reports to document test results prior to delivery to customer
- Contractor: SearchPro Solutions
6KC3P-Systems Engineer 3 - 62U-Reliab, Maintain & Sys Health
The Boeing Company
Ridley Park, PA
09.2015 - 04.2016
- Evaluated customer and operational needs to define and coordinate system performance requirements, integrated technical parameters and assured compatibility of all physical, functional and program interfaces
- Developed the planning, organization, monitoring and implementation; including decomposition and allocation, of requirements management processes, tools, risk, issues, opportunity management and technology readiness assessments
- Contractor: SearchPro Solutions
Reliability Engineer – Systems Integration & Test
Collins Aerospace (Formerly: Rockwell Collins)
Cedar Rapids, IA
02.2014 - 09.2014
- Lead the Systems Integration & Test team, in the development of Technical Publications to ensure delivery of Operational Maintenance Manuals (OMMs) in support of the new Common Range Integrated Instrumentation System (CRIIS) program given aggressive schedule.
- Efforts included the development of troubleshooting guide, fault tree analysis (FTA), and various technical procedures
- Carried out the completion of the gathering of Built-in-Test information and coverage regarding the procured modules and Commercial-off-the Shelf (COTS) equipment utilized in the CRIIS design
- Contractor: Technical Resources Unlimited
- Clearance: SECRET
Principal Systems Engineer – Reliability, Maintainability & Safety
Raytheon Missile Systems
Tucson, AZ
02.2013 - 09.2013
- Organized and managed Failure Reporting and Corrective Action Systems (FRACAS) for the Standard Missile programs - Technical interaction with customer, Responsible Engineers (REs), design and chief engineers for multiple design updates and fielded systems - Monitored integration and production level testing activities
- Completed Failure Mode Effects and Criticality Analysis (FMECA) to support the inclusion of Plastic Encapsulated Microcircuit (PEM) parts into the design for the Joint Air-to-Ground Missile (JAGM) program; Including Failure In Time (FIT) rate determination, and piece-part analyses
- Contractor: Technical Resources Unlimited
- Clearance: SECRET
Level 4 Reliability Engineer, BAMS Program (Reliability, Maintainability & Affordability)
Northrop Grumman Aerospace Systems
Melbourne, FL
08.2010 - 07.2012
- Directed FRACAS activities on assigned systems / subsystems (Propulsion, Electrical Power System and Structures) - Included Root Cause Analysis and troubleshooting - Identifying failure trends and following them to closure
- Lead effort to ensure Environmental Stress Screening (ESS) procedures were adequate for effectively reducing latent defects on Air Vehicle components
- Directed the Reliability Design, FMECA and Prediction data for assigned systems (Communications, Navigation, Propulsion, Flight Controls, Electrical Power System and Structures) reflecting the latest configuration and system information
- Assisted in generation of System Safety documents; such as Risk Hazard Analysis (RHA), Safety Compliance Analysis (SCA), Safety Assessment Report (SAR)
- Coordinated requirements allocation and interface definition studies to translate customer requirements into hardware and software specifications
- Applied engineering principles to assess design compliance, synthesize rationale and justification for waiver requests for requirement and hardware non-compliances
- Performed technical planning to identify and define the system integration, verification & validation, cost, and supportability & effectiveness approach for total systems
- Clearance: SECRET
Systems Engineer Senior, US TRANSCOM Program
Lockheed Martin Information Systems & Global Solutions
O'Fallon, IL
04.2007 - 06.2009
- Developed a Commercial Off-the-Shelf (COTS) Roadmap to illustrate and describe the ‘path-forward’ regarding upgrading the various software products currently installed on our assorted servers
- Participated in the development of the Global Air Transportation Execution System (GATES) proposal, in an attempt to bring new business to the organization
- Responsible for maintaining System Architect Models; Server/Network Hardware Architecture (including Infrastructure, Hardware and Product Interaction), Functional/System Flows and Requirement views for the US Military’s Distribution Network Supply Chain Management operations
- Responsible for generating DODAF Viewpoints and Models
- Supported Pre-Planned Product Improvement (P3I) Database Warehouse Program with USAF customer
- Responsible for developing test plans, test conditions, test data to ensure the quality of the Unix Platform
- Conducted data testing to confirm the processing logic implemented to populate the database as well as to retrieve the data for the reports is functioning properly and satisfies the detailed design
- Clearance: SECRET
Systems Engineer Staffer, JSF (F-35) Systems Reliability, Maintainability & Safety Technical Lead
Lockheed Martin Aeronautics
Fort Worth, TX
11.1998 - 03.2007
- Planned, managed and achieved (Technical Requirements Development, Budget/Schedule Allocations):
- - Air Vehicle Failure Mode and Effects Criticality Analyses (FMECA) Included managing twelve subject matter expert Reliability engineers, chairing the FMECA Review Board and briefing Chief Engineers & customers during various meetings/Design Reviews
- - Reliability Mission Modeling - Included the development of Reliability Block Diagrams based on JSF-platform missions
- - Air Vehicle & Mission Systems Failure Immunity (FI) tasks to ensure Flying Quality requirements have been met/verified - Included managing four System Safety engineers and conducting training of a variety of engineers on Fault Tree Analysis (FTA) tools. Ensured horizontal integration across Integrated Product Teams (IPTs)
- Systems Failure Mode Effects Testing (FMET): Included Test Plan, Test Procedure, Test Execution and Test Results documentation, Software patch writing/insertion to simulate Hardware failures
- Responsible for management of Reliability Growth Testing, Reliability Design, Weibull Analysis, Accelerated Life Testing, and Fault definition & analysis
- Developed and executed plans for Quality Improvement Team (QIT) activities and improved customer satisfaction - Increased knowledge of Reliability & Maintainability design principles and effectively communicated design issues/solutions to design engineers
- Key role with critical elements regarding Flight Test coordination leading up to and following First-Flight
- Systems Safety Liaison and Risk Assessment Manager
- Assisted in generation of System Safety Program Plan (SSPP), Functional Hazard Analysis (FHA)
- Performed Virtual Human Factors Assessments for maintenance accessibility
- Performed Prognostic/Diagnostic Health Management (P/DHM) analyses to provide optimized operational efficiency, ensuring safety & reliability of aircraft systems, and minimize superfluous costs through predicting the failure in components and/or detection, diagnosis and prognosis of degradation or faults in a vehicle system or its components to identify trends and support long-term fleet operations
- Lead research and development teams with supplier and customer insight
- Performed SpE integration for all new LM Aero Business Proposals and Systems vendor selections - Included development and coordination for: Procurement Packages, Engineering Change Documents, Life-Cycle Cost Studies, Statements of Work and Specifications. Focal point for all Customer Fact-Finding Efforts
- Clearance: SECRET
Education
Bachelor of Science - Electronic Engineering
DeVry University
Kansas City, MO10-1998
Skills
- Automation tools
- Data center management
- System testing
- Process documentation
Timeline
Lead Systems Engineer - RMSS
Honeywell
09.2024 - Current
Principal Engineer – Electrical
Northrop Grumman Space Systems/Launch & Missile Defense
11.2019 - 09.2024
Sr Systems Engineer – Space Network Ground Segment Sustainment (SGSS)
General Dynamics Mission Systems
09.2017 - 08.2019
Sr Systems Engineer – Engines & Power Generation Systems (Technical Lead)
Honeywell Aerospace
07.2017 - 09.2017
ILS Systems Engineer 4 – Systems Integration & Verification
The Boeing Company
10.2016 - 03.2017
6KC3P-Systems Engineer 3 - 62U-Reliab, Maintain & Sys Health
The Boeing Company
09.2015 - 04.2016
Reliability Engineer – Systems Integration & Test
Collins Aerospace (Formerly: Rockwell Collins)
02.2014 - 09.2014
Principal Systems Engineer – Reliability, Maintainability & Safety
Raytheon Missile Systems
02.2013 - 09.2013
Level 4 Reliability Engineer, BAMS Program (Reliability, Maintainability & Affordability)
Northrop Grumman Aerospace Systems
08.2010 - 07.2012
Systems Engineer Senior, US TRANSCOM Program
Lockheed Martin Information Systems & Global Solutions
04.2007 - 06.2009
Systems Engineer Staffer, JSF (F-35) Systems Reliability, Maintainability & Safety Technical Lead
Lockheed Martin Aeronautics
11.1998 - 03.2007
Bachelor of Science - Electronic Engineering
DeVry University