Lucas Amaral Sales

Experience

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  Max-Planck-Institut für Eisenforschung GmbH

  Apr 2008 - Feb 2009

  Intern - Materials Engineering

  • Software programming to support investigation of new alloys, mainly using MATLAB.• Automation of several handmade processes.• Conducting X-Ray experiments on diffractometers and synchrotron radiation facilities on major Europe research centers (Germany and France).• International publication of 2 scientific articles.

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  Souza Cruz

  Jan 2011 - Jul 2011

  Intern - Projects/Process Engineering

  • Interfacing production & marketing departments, supporting new product and processes projects execution.• Leading communication plan for ongoing projects, following PMO and benchmark guidelines.• Full implementation of new design for product cell, controlling a budget of +R$600k, which was delivered on time.

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  GE Renewable Energy

  Jul 2011 - now

  • Technical ownership and systems engineering leadership for global Root Cause Analysis (RCA) of major components and failures with multiple sub-system interactions;• Define systematic technical path for major wind turbine fleet issues investigation, such as blades, control systems, machine head and systems dynamics and stability;• Lead multidisciplinary teams of sub-systems engineers (controls, electrical, blades, machine head, tower, power performance, stability, loads and operability) to drive root cause identification, containment and corrective action technical definition, field implementation and validation;• Act as technical point of contact between GE and customers or third party agencies to relevant RCAs as well as internal ownership and report out to different leadership levels;• Drive system-level tradeoffs and risk assessments for corrective actions, such as component life or reliability versus Annual Energy Production;• Perform and interpret system stability assessments, main component loads analysis and power performance impacts;• Define requirements and lead data analysis deep dive for field test validation measurement campaigns, such as LiDAR, main component strain gauge, oscillations and control systems;• Collaborate to a continuous improvement mindset by recording and implementing lessons learned from RCA into design processes, auditing and proposing improvements to existing design practices;• System level ownership of a major wind turbine model in North America;• Technical lead wind turbine cross-platforms programs for Stall Induced Vibration & Vortex Induced Vibration (SiV/ViV) regarding product safety, field practices, novel controls and hardware mitigations;• Technical lead implementation of IEEE2800 (Interconnection and Interoperability of Inverter-Based Resources Interconnecting with Associated Transmission Electric Power Systems) requirements on wind turbines; Show less • Develop, optimize and validate wind turbine power performance controls and hardware targeting higher efficiency power production;• Model, simulate and understand wind turbines and their various subsystems’ combined effects on power performance;• Investigate power performance on wind farm & wind turbine levels for multiple customers and platforms using analytics tools on turbine operational data. Use big data and thorough assessment to propose technical solutions to optimize power production such as new control systems, aerodynamic features, from concept to implementation;• Lead and guide wind power performance test execution through IEC61400-12-1 and additional internal technical guidelines as well as evaluate and challenge test data along with certification bodies;• Modeling and development of Wind Integrated Solar System (WiSE) methodology for power performance forecast. Creation of wind turbine power curves for multiple environmental and operating conditions through detailed technical and commercial analysis, modeling risks and potential business implications;• Power performance engineering product owner of leading wind turbine platform in the US, responsible for implementing and integrating new technologies with multiple subsystems (loads, controls, electrical, etc);• Multiply team knowledge to accelerate customer responsiveness by training team members on wind turbine modeling, performance testing, wind turbine operational behavior, etc. Show less • Lead Root Cause Analysis (RCA) of wind blade failures and systematic defects, liaising with field techs, services, repair companies, manufacturers in order to drive containment and corrective actions, focusing on wind farm availability and product integrity;• Technical evaluation of installed wind blade fleet in Latin America, responsible for evaluating blade inspection and repair reports, as well as providing guidelines to third party companies on blade specific activities;• Key technical contact within services organization to support answering customer and site team questions regarding blades. Evaluating trade-offs between blade repair and inspection campaigns versus turbine availability. Show less • Lead quality assurance, quality control, compliance and fulfillment activities of blades suppliers in 3 different suppliers in Brazil. Lead the resolution of supplier quality issues and manage suppliers to meet/exceed company quality requirements, solving product quality issues through effective corrective & preventive measures and drive continuous improvement of supplier's quality performance;Few quantitative achievements:1) Supplier Product Deviation reduction of 58% (2015-2016);2) First Pass Yield improvement of 26% (2015-2016);3) Corrective Actions reduction of 65% (2015-2016);4) Internal audit findings reduction of 75% (2015-2016).• Lead cross-functional activities with project & engineering teams to deliver business priorities in the region, with sourcing team on new suppliers and product introduction and as a support to logistics team on safe and on time delivery to GE final customers.• Provide warranty support and participate in potential failure root cause analysis and investigations that may affect the product throughout years of post-commissioning operation.• Lead a team of 5 quality inspectors in different factories, supporting them in handling conflicts with suppliers while assuring product integrity. Also, provide them technical guidance and develop working tools (such as Digital platform for supplier audits and component inspection). Show less The Operations Management Leadership Program (OMLP) is a 2-year program consisting of 4 rotations that allow members to build leadership and functional skills through challenging rotational assignments and world-class training such as lean, six sigma and operations finances. During my program I have experienced the following positions:• GE Oil & Gas, 01/13 – 06/13, Role: Operations Master Scheduler & Project Leader• GE Renewable Energy, 07/12 – 12/12, Role: Supplier Quality Engineer• GE Corporate, 01/12 – 06/12, Role: Environmental, Health & Safety Projects Leader• GE Oil & Gas, 07/11 – 12/11, Role: Operations Lean & Quality Projects Leader Show less

  • Senior Systems Engineer

    Aug 2021 - now

  • Lead Performance Optimization Systems Engineer

    Nov 2017 - Jul 2021

  • Lead Fleet Reliability Engineer

    Sept 2016 - Nov 2017

  • Lead Supplier Quality Engineer

    Jul 2013 - Sept 2016

  • Operations Management Leadership Program - OMLP

    Jul 2011 - Jun 2013