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Work experience


Manager of Engineering

Churchill Medical Systems (Vygon USA)

Medical Device Manufacturing Industry

Responsible for all Engineering Operations within the Dover, NH manufacturing facility. This also includes providing technical support for our corporate headquarters in Montgomeryville, PA.

Responsible for:

  •  Engineering Operations
  •  Quoting and New  Product Development
  •  New Device R & D
  •  Manufacturing Process Engineering

 Notable accomplishments include:

  • Protocol and Validation System: A prime opportunity recognized  early in my tenure as an Engineering Manager, was to establish an organized protocol system for documenting validations. Answering to this challenge, a protocol system was developed and successfully implemented. This system has remained in place and continues to grow.
  •  Quote Tracking System:  Project delegated under a “Goal Incentive” platform. Designed program  to provide key quoting metrics such as scheduling, turnover, purchase order to quote ratio. System provided key outputs for dashboard performance metrics.
  • Business Systems Migration:  Project team member of a multi-facility migration and consolidation to a common business system software (MAS 200). Project was completed within budget and systems went on line within the timeframe scheduled. Successful migration to the new system has been realized. All business, within 3 facilities, are on line and operating successfully 
  •  Re-Validation of EtO Sterization process : Providing support to Quality Control during a time of a streamlined staff base, my task was to manage the entire Sterilization Revalidation project. This include, writing protocols, designing logistics and combining efforts between the sterilization facility and the testing laboratory. Created physical mock-up loads to simulate “worse-case” densities. Researched and determined a master validation load that best represented a vast product line of possibilities. Conducted sub-lethal, half and full cycle to a sterility level of 10-6. Scope of testing also included  evaluating EtO residual burn- off in accordance with applicable ANSI standards.

Manufacturing Engineer/Project Manager

Disetronic Sterile Products

Medical Device Manufacturing Industry

Project Manager.

Insulin delivery extension set: Automation Project. Demonstrated solid project management skills by managing the outsourcing project for a custom automated manufacturing system. Efforts included complete definition of system requirements and product specifications, conducting all UV curing research in order to define system process parameters, scheduling of milestones and design reviews, and all machine validation activities. All design and manufacturing phases occurred in Italy requiring frequent communication, overseas travel for design reviews and factory acceptance testing. The automation was eventually integrated into production along side the existing manual assembly line.

Automation Station Retrofit Project. Outsourced and managed the design process for an automated station retrofit project. Following the design phase, my accomplishments consisted of; coordinating parts to be manufactured, procurement of 3rd party components, and complete hands on system installation. Physical system was successful and operational on the first trial run.

Manufacturing Process Engineer.

Conducted medical device manufacturing transfers from process planning and development stages through process, product and sterile packaging validations. Development and execution of DOE. Developed manufacturing and quality process documentation. Protocol development and management of execution for all validation stages. Analyzed validation data for process capability determination and compiled validation reports.

Other activities:

  • Equipment maintenance and troubleshooting.
  • Set up and maintain SPC for production monitoring.
  • Complaint investigations.
  • UV curing system parameters.
  • Design and build of custom production equipment.
  • Plant expansion layouts.
  • Value stream mapping of Standard Operating Procedures.
  • Project budgeting for capital expenditure proposals.

Design Engineer/Project Manager

Renaissance Design Incorporated/Hexel Corporation

Engineering and Design Service Industry

Design Engineer

Design Projects using Unigraphics solid modeling, included: hip implant forging design, proprietary biopsy apparatus, inline skate insole, tooling design for automotive component machining centers.

Project Manager

Capitalized on colleague networking and arranged for the opportunity to submit a bid (and was awarded the contract) for the development of high speed rotary newspaper folder for a leading printing press manufacturer. As the Project Manager, I provided leadership to a talented team of Designers and Engineers to bring the project to completion within schedule and budget. The entire press system was successfully showcased at major world-wide printing expositions.

Production Launch Team

The team’s goal was to prepare a developmental machine tool for a production manufacturing launch. Contribution efforts included; analyzing and comparing prospective manufacturing business systems software, develop manufacturing and assembly process documentation and physical production inventory set-up and logistics. Component issues with OEM equipment became a major issue and the production launch was never realized.


Project Design Engineer

DWC Associates

Automation Design and Build

Project management of prototype design and build projects.  Responsibilities for this position were widespread, including but not limited to: machine design and detail drawings using Cadkey CAD software, project scheduling, component sourcing and procurement, manufacturing support, inventory control, hands on metal-work fabrication skills, industrial wiring of automation components, testing and prototype validations, prototype to production transition and factory installation assistance.


Design Engineer/Change Reccomendation Coordinator/Assembly Engineer

Heidelberg Web Press (Harris Graphics)

Printing and Graphics Arts Industry 

Design Engineer

Engineering Operations Department. Design printing press system layouts including integration of all ancillary systems. Identification and release of all BOM’s to production planning and manufacturing. Participated in customer proposal and design reviews meetings. Day-to- day operations also included providing manufacturing and field service support.

Change Recommendation Coordinator

Created systems to reduce an influx of manufacturing change requests coming from three different facilities. Managed a short-term task-force of Designers to implement the systems that resulted in an 85% backlog reduction in less than 9 months.

Assembly Engineer

This position was my 2nd semester college co-op position. I was given the opportunity to help implement an experimental “start-up” group, with the goal of reinforcing communication between the Engineering Department and the Assembly floor. The need for this function was fully realized as the workload consumed available resources. The success of the pilot group quickly grew into a requirement for a full scale Assembly Engineering Department.


Mechanical Draftsman

P.K.Lindsay Co

Compressed Air and Industrial Equipment Industry

It is my honor to have known Mr. P.K Lindsay, the founder and name sake of the P.K. Lindsay Company. Lindsay was a leading manufacturer of industrial air compressors. My earliest memories go back to when, my father was P.K.’s Sales Manager. Occasionally I would get the chance to go to the factory after hours. Mr. Lindsay would proudly show me around his facility and explain how the parts machines were machined and assembled. I remember being  fascinated with the engineering department and all the drawings. In retrospect, this was the genesis of my engineering influences.

As a young engineering student, I had the opportunity to work for the Lindsay company, to satisy my college co-op requirements. I became directly involved in the final prototype stages of a diesel-powered air compressor. This was my first opportunity to utilize my developing drafting skills in a professional capacity. But moreso, this gave way to new experiences of hands-on fabrication, assembly, debug and validation testing.



Wentworth Institute of Technology

Bachelor of Science, Mechanical EngineeringTechnology                               

 Graduated 1987.

Associate Degree, Mechanical DesignTechnology   

Graduated Dean's List 1985.

Associate Degree, Mechanical DraftingTechnology

President's Honor Roll. Graduated Dean's List 1984.                                                                     


Project Management
Statistical software.
Not designing with CAD currently. CAD systems used throughout my career include AutoCAD (1992-2008), Unigraphics 1986 - 2000, Cadkey (1994-1996), Solidworks, 2006
ERP and Quality Systems Software
Mas200 business management systems software and Grand Avenue Quality Systems Software.
Microsoft Office Products
Advanced skills and proficiency using MS applications: Word, Excel, PowerPoint, Project and Outlook.    
Crisis Management
Albeit, my least favorite skill.


Christopher Clement

 Former engineering colleague.

David Lloyd

Veronica Haug

John Sasso

What others are saying

"John is an outstanding and talented individual who immediately became an integral part of our product design, manufacturing and quality control team. He get’s along with all levels within an organization, is hard working and diligent and takes a proprietary interest in the success of an organization. He is the kind of employee that any business would be glad to have and frankly, would be lucky to have part of a high-tech product development and manufacturing company".

(Excerpt from recommendation letter)

-John Sasso

Former Owner/President Churchill Medical Systems

“I hired John before I knew him. he turned into a natural leader quick to learn and abilities galore. He was worth every penny I paid him and more!”

-Richard Hillow

Financial Advisor

(former engineering collegue DWC Associates)

What John can do for you

 I am a dynamic and forward-thinking management professional who offers technical wisdom and a motivating style of leadership to promote teamwork, peak performance and a passion for continuous betterment.

Drawing from experiences that span a diverse range of industries, my ability to assess new situations and adapt quickly are traits I offer. These traits have fueled my success, allow me the opportunity to add fuel to your success. 

I take pride in my technical insight and ability to understand and differentiate the details while maintaining focus on the bigger picture.

My motivation is fueled by a balanced lifestyle, a vital sense of well-being, deep pride from accomplishments made and the excitement of knowing there are more to come.