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Peter L Mischler Engineering

fulfilling Your needs for a

Partner / Leader / Mentor / Elder

Innovation is a game of Leap-frog and not Follow-The-Leader

Who ARE WE:

Welcome to PLME Consulting LLC. We were founded on over 40 years of Engineering experience in manufacturing, automation and production solutions with the purpose of leveraging that experience to augment your Team with the Partner, Leader, Mentor or Elder you need to advance your business needs. If you are wondering what we mean by "Elder", it refers to a mentor (like a "Tribal Elder") who passes their years of experience, knowledge and wisdom on to give the next generation a leg up headstart. (To see more about Modern Elders get: "Wisdom @ Work" by Chip Conley)

About PLME Consulting

01

History

As life-long learners we have grown up primarily in the Special Manufacturing Equipment space. With the understanding that "The BOX is the hiding place of the unimaginative and is only a chalk outline that there should be no fear of stepping outside the BOX."

02

Approach

With an immersive management style we build on past experiences and blend them with new concepts to find the optimal solution to the problems at hand. We are comfortable with helping you lead a Team or just blend in as another member of a flat/equal Team.

03

Values

PLME Consulting LLC believes that "Innovation is a game of Leap-Frog and not Follow-The-Leader." To acheive true innovation we need to collect, compile, comprehend, consider and consildate creative concepts. We value honest, ethical and transparent design process.

Experience

2016-2024 Engineering Manager: Bourn & Koch, Rockford, Illinois Chief Engineer/Technical Director: Focused on “all things technical”. Discover and distill Customer manufacturing needs and determine a best-in-class solution that fits the Company’s capabilities. Find solutions that leverage existing standard assemblies and/or generate new assemblies that drive toward future standards. Generate system concepts, resource requirements and material costs for use in Sales Pricing. Determine effective automation and that can be incrementally implemented as the Customer’s needs grow. Lead interpretation and modification of Legacy design data (drawings, BOMs, methods, etc.) from 2500 years of Engineering from the 28 brands the Company owns the IP for. I had occasion to update drawings greater than 100 years old.Engineering Manager: Performed duties from Director Level to hands-on in the trenches design tasks. Participated in Company Strategic Planning, budgets, workforce hiring and development. Lead a team of 10-12 Engineers (Mechanical, Electrical, Software, Automation) to develop new Machine Tool products. Designed a modern version of Blanchard conceived to simplify Assembly and allow Lean moving line Assembly. This product led to the development of a product family (MT3) that was modular for Assembly and Functionality with Turning, Milling, Grinding, 3D Printing and other capabilities. It included a 6-axis Fanuc Robot with a common gripper assembly to change tools and spindles including recovery software to avoid need for robot operation skills in production. Lead the fast-track development of a Blanchard Chuck Controller when the Vendor closed suddenly, and the alternatives were insufficient. Rewrote the C# HMI (learned C# on the fly from reading code and asking ChatGPT for help) for the MT-Blanchard when it was converted to a PC Front End and no Software Engineers were available. Developed two different custom machines for the DOE based on the platform of a future size of MT3 machine. Led Corrective Action and Continuous Improvement Projects utilizing Lean Techniques. Created a lean layout plan for the entire assembly facility that has stood 7 years of individual area lean projects as “the best solution”. 2007-2016 Mechanical Engineer: Fives, Hebron, Kentucky Development Engineering Manager: Managed a 1.5-million-dollar development program for a large new Aerospace High Speed Milling Machine. Developed concepts; managed and directed Engineers and Designers; assisted in assembly of the first completely new machine design on an accelerated schedule for display at IMTS 08. Developed the modular design of machine variations to expand the family of machines. Used ProE & UG solid modeling. Worked on Lean & 6 Sigma initiatives to increase modularity and minimize Assembly & Installation labor costs. Worked with consultant experts to develop liquid nitrogen delivery to the tool system for a 5-axis machine for demonstration at IMX Show on an extremely aggressive schedule after the sudden illness of the primary Engineer. 2005-2007 Mechanical Engineer: Woodward Governor Company, Rockford, Illinois Project Engineer: Took over project responsibility to complete Certification and close out all Specification Compliance and internal procedure issues on a Fuel Metering Unit program. Worked closely with the Customer and all areas of the Company to facilitate a smooth transition into high volume production.Staff Engineer: Worked with a team of engineers to write test plans, perform tests and write reports to obtain FAA and Transport Canada Certification of a jet engine Fuel Metering Unit. 2003-2005 Mechanical Engineer: Ingersoll Machine Tools, Inc., Rockford, Illinois Sr. Staff Engineer: Led a team designing a new large Vertical Boring Machine. Performed and directed mechanical and utility concept and design and coordinated with electrical design. Performed Customer reviews and interfaced with Customer’s Facilities group on foundation design. Maintained a very aggressive schedule with minimal resources & a tight budget while maintaining project security requirements. 2003-2004 Project Engineer: LM Aero, Fort Worth, Texas AutoDrill Engineer: Aided LM Aero in completion of building the AutoDrill system by Cincinnati Machine after Ingersoll closed. Communicated design criteria and specifications and helped troubleshoot the build. Ensured LM Aero received the machine in a cost effective and timely manner while maintaining the original specifications. Determined and mitigated risks as required.

1988-2003 Mechanical Engineer: Ingersoll Milling Machine Co., Rockford, Illinois Staff Engineer: Supported other Engineers in advanced technology areas of projects through research, testing, analysis and calculations. Worked closely with customers and developed several machines and subsystems to best fulfill their needs. Trained as a QS 9000/TE (ISO 9001) internal auditor. Performed FEA analysis using GeoStar, FEMAP & CosWorks. Worked to develop and lead a team to Value Engineer (remove cost without removing functionality) and build a new multi-machine AutoDrill system.Project Management/Engineer: Acted as customer and supplier team contact and coordinator for both contractual and technical issues on a DARPA funded new technology development linear motor machine. Coordinated designing, detailing and checking of assemblies; wrote specifications; and interfaced with Manufacturing, Assembly and outside vendors during the rebuilding of an existing transfer line, a High Velocity Machining Center and a special multi-machine system. Design Engineer: Used Solid Works, Pro/Engineer, CADAM and AutoCad to concept and design machine assemblies and created detailed part drawings including all required GD&T. Worked with FMEA and DFA/DFM design techniques while designing several complex automatic transfer lines.Shop Service Engineer: Assisted Assembly and Manufacturing personnel by quickly determining the most efficient solution to shop related problems.Runoff/Quality Engineer: Interpreted customer part print tolerances; calculated in process tolerances; created CMM and hard gage inspection procedures; analyzed inspection results; determined the corrective actions necessary to achieve the SPC requirements; and interfaced with the customer on several transfer line system. 1984-1988 Mechanical Engineer Co-Op Student: Giddings & Lewis, Fond du Lac, Wisconsin 1983-1984 Groundskeeper & Maintenance: Countryside Golf Course, Kaukauna, Wisconsin 196?-1984 Farmhand: Mischler Family Dairy Farm, Kaukauna, Wisconsin

Patents:

8,752,811 - Symmetrical head mounted tuned mass damper Abstract: A tuned mass damper is designed for a machine tool head that moves in the X, Y, and Z directions and rotates around a C-axis that is coincident with the axis of an arm that supports the head. The damper comprises a pair of damper masses symmetrically arranged around the head. Each damper mass has a center of gravity which is approximately in the geometric center of the mass. A resilient mounting is provided for each of the damper masses allowing the damper masses to damp out vibration in the X and Y directions regardless of the orientation of the head. 8,662,802 – High rigidity moving column horizontal machine tool Abstract: A rigid design for a machine tool having perpendicular X, Y, and Z axes includes fixed X-axis frame members at the back of the machine, fixed Z-axis vertical frame members at the front of the machine, and fixed upper and lower Z-axis frame members rigidly attached to the fixed X-axis frame members and the fixed Z-axis vertical frame members. The frame members form a fixed, rigid, closed force loop design. A movable Y-axis column is bifurcated and a headstock is mounted in the center opening of the column. The headstock is advanced and retracted relative to the workpiece by moving the Y-axis column and the headstock relative to the workpiece. Because the headstock is fixed relative to the Y-axis column, the unsupported portion of the headstock relative to the Y-axis column does not change as the Z-axis position of the headstock changes. 8,141,856 – Pallet loader and manipulator Abstract: A pallet load stand and manipulator allows a pallet to receive a workpiece and the workpiece to be clamped to the pallet while the pallet is in a horizontal position. Once the workpiece has been clamped to the pallet, the pallet may be rotated to a vertical position so that the pallet may be loaded onto a machine tool that operates on a workpiece with the pallet in the vertical position. The pallet may also be rotated to an intermediate position, similar to an artist's easel, in which the pallet is held in an inclined position, between the horizontal and vertical positions by positive locating assemblies and positive stops. 7,810,539 – Compaction roller for a fiber placement machine Abstract: Tools for compacting composite parts are disclosed. These tools are used while layers of composite material, such as tows or laminae, are being deposited onto a fabricating surface, such as a mold or other forming tool. The compacting tool is typically divided into a series of narrow segments, each segment able to advance or retreat individually so as to conform to the surface of a composite part being formed. Pressurized fluid, such as air or hydraulic fluid, or non-pressurized internal bladders with incompressible fluid, are used to evenly apply pressure to the segments in order to compact the material with which the tool and the segments are in contact. The compacting tool thus helps eliminate voids and helps the material conform to the desired shape on the forming tool. 7,653,974 – Pallet handling system for machine tool Abstract: A machine tool has pass-through pallet loading allowing pallets to be loaded or discharged from either side of the machine. The pallet receiver is mounted on the X-axis of the machine, and the pallet is loaded onto the pallet receiver with the pallet in a vertical orientation. Cross axis rollers on the pallet receiver support the pallet and spacing rollers maintain the pallet spaced from Z-axis locating pads as it moves to a centered position on the pallet receiver. The Z-axis pads present a relatively large surface area to the rear face of the pallet, and are configured to provide vacuum clamping to lock the pallet in all three axes once it is centered on the pallet receiver. A rotating key is provided to center and lock the pallet relative to the pallet receiver before the vacuum clamping is applied. 7,547,270 – Machine tool with optimally positioned operator station Abstract: An operator station is positioned on the outside of a machine tool on the same side of the machine as the tool magazine and the automatic tool changer, to improve the ergonomics of the machine by keeping the tool loading access as close as possible to the operator. This location also allows easy visual access to the tools in the magazine and in the ready position in the tool changer. An angled “tunnel” window passing across the front of the tool magazine and the Y-axis column allows direct visual observation of the working zone of the machine tool from the operator station. A door on the side of the machine allows access from the operator station to a utilities panel located just inside of the door permitting ready operator access to switches, valves, fill points, filters and gages that are located on the panel. 7,534,078 – Consistent rigidity construction arrangement for a machine tool Abstract: The frame of a machine tool forms a closed force loop design that surrounds a workzone containing the spindle head. The X and Y-axis drive motors are mounted on stationary elements of the machine. The Y-axis column is fixed, and supports a Z-axis ram. The mounting and positioning of the Z-axis ram minimizes the change in droop and the effects of acceleration forces on the Z-axis structure. The X, Y, and Z-axis drive motors are all mounted outside of the workzone to shield them from contamination and debris generating during the machining process, and for ease of maintenance. 7,509,718 – Machine tool with selective drive motor positioning Abstract: The frame of a machine tool forms a closed force loop design that surrounds a workzone containing the spindle head. The X, Y, and Z-axis drive systems are all mounted outside of the machine to shield them from contamination and debris generating during the machining process, and for ease of maintenance without having to enter the machine or remove workzone covers to access them. The X and Y-axis drives are mounted on stationary parts of the machine, eliminating the need for flexible cables to power and control these drives and reducing the mass of the moving elements of the machine. Publication 20140054885 – C-axis ring for a machine tool Abstract: A rotary joint for a fluid is in the form of a hollow ring having an upper half and a lower half that are rotatable relative to one another in an X-Y plane around a C-axis. An inlet tube admits fluid to the ring and an outlet tube exhausts fluid from the ring. Both the inlet tube and the outlet tube are displaced from the C-axis. An inlet elbow is positioned in the hollow ring and has a rounded bend in the interior of the ring that directs fluid around the circumference of the ring.

Past Project Customers:

  • Boeing / McDonald Douglas Lockheed Martin (LM Aero) Department of Energy Department of Defense National Labs (LLNL, LANL, ORNL, …) DARPA Pratt & Whitney General Electric Woodward Governor Brek Manufacturing Caterpillar John Deere Mack Trucks Komatsu Ford Chrysler General Motors Tata Motors Kentucky Trailer Corning

Past Projects:

Modular Multi-tasking (Mill, Turn, Grind, …) Machining System Robotic Tool & Spindle Changing System for Multi-tasking Machine Custom Specialized 3D Printing Systems Vertical Grinder Optimized for Automation and Lean Assembly Custom Drilling and Fastening Machine for Trailer Decks Modernization and Enhancement Packages for Remanufactured Machines Turning Turret for Gear Hobbing Machine 5-Axis High Speed and High Acceleration Milling Machine Modular High Speed 5-Axis Precision Mill & Trim Gantry Machine Custom Large Machine Wrist for Multi-Function Fiber Lay-up Gantry Custom Large Vertical Boring Machine (Over 100 ft Tall) Wide Band Fiber Placement Head Custom Large Wing Drilling Machine (for F35 Fighter Jet) Custom Large Vertical Trunnion Machine for 8-20 Cylinder Engine Blocks Custom Configurable Wing Spar Machining and Assembly Machine Automotive Engine Block Transfer Lines Automotive Engine Block Machining Center Fixturing Advanced High Speed Hydrodynamic Spindle System Custom Precision High Speed Machine with Vibration Control for DARPA