A proven problem solver with experience in manufacturing, process development, quality engineering, and R & D in adhesives, coating, electronics and electrochemistry.Work has resulted in plant awards, patents, cost savings, resolution of long term problems, quality and efficiency improvements.
Presented papers on: No Clean Wave Soldering, VOC Free Conformal Coating
PROCESS AND MANUFACTURING ENGINEERING:
·Patented process for spray coating application. Process resulted in trade publications, articles and seminar presentations. Assisted material supplier with in-plant demonstrations for other customers.
·Sourced and designed injection molds, cutting dies and assembly tooling. Developed, qualified, justified and sourced non-stick coatings for injection molds.
·Justified, specified, sourced, ordered and installed new production equipment.
·Created new and improved processes and procedures for potting, soldering and production tooling for new and current products.
·Specified, selected, qualified and sourced materials.
PROCESS OPTIMIZATION/LEAN MANUFACTURING:
·Reduced required run time from 24/7 to 2 shifts by balancing line, improving yield and bottlenecks and reducing changeover time without expending any capital or increasing labor on remaining shifts.
·Performed run at rates, capacity analysis, and time and motion studies. Identified bottlenecks, constraints and sources of waste. Presented data to management and customers.
·Developed new process that saved app. $0.25/unit vs. the previous method by automating and combining multiple operations. Created new screen print stencil designs, tooling and eliminated a high cost material. Justified required investment and raw material price increase.
·Reduced solder and solder paste material cost by over $100k/year by qualifying second source.
·Primary customer contact for launch, support and field issues. Created and led cross functional teams and managed open issue lists. Closed issues at customer.
·Utilized 8D, DDW, 5Y, 5P, Pareto, DOE, controlled experiments and other techniques to improve product and process. Developed and implemented corrective action. Maintained open item lists.
·DFM/DFA/DMAIC. Utilized FMEA, stack analysis, MSA, process capability studies, constraints and lessons learned to improve new and existing products.
·Created FMEA, Control Plan and RPN reduction plan. Created, led and participated in FMEA teams.
·Lead engineer for identifying and implementing corrective action for warranty issues. Worked with Design Engineering, PCB and other suppliers to implement corrective actions.
·Completed all APQP and PPAP requirements and documents. Created and managed cross functional teams. Maintained and drove open item lists with design, suppliers, the customer, manufacturing, and other groups. Negotiated launch and PPAP requirements with customers.
·Developed quality system for new startup. Procedures included incoming materials, process control and production data collection, layered and process audits and charts and reports.
·Performed customer and third party supplier audits. Worked with suppliers to identify and correct the true root cause. Created and maintained open item lists. Implemented containment.
·Created and managed budget, schedules, costing and qualification plan for new projects up to $500k. Created all process documentation. Managed project timeline and budget.
·Successfully launched new PCB process material and manufacturing process in Mexico. Responsible for all aspects of launch and delivering project on schedule.
·Created corporate procedures and activities related to supplier quality, quality, production and other systems.
·Coordinated controlled shipping activities with suppliers, their suppliers, and production plants. Created charts and management reports for tracking over 100 issues. Maintained database and drove issues to closure.
·Expert in MS Office, MS Excel, Minitab and other software packages.
·Basic and applied R&D in electrochemistry, coatings and electroplating.
·Supervised engineers, technicians and hourly employees.
·Eliminated 75 tons per year of reportable airborne emissions. Reductions led to Environmental Award.
·Completed 6 sigma green belt training.
·Conducted training workshops:
·GM Certified CS2 Provider Quality Engineer (PQE), GM Drill Deep and Wide (DDW) Trainer.