Paul Mueller

Paul Mueller


A Project Engineer,  Project Manager, and Plastics Engineer with over twenty years of product development experience managing multiple projects from cradle to grave. A vast experience working for several dynamic companies  developing a vast array of products from consumer, medical,  and industrial products to custom machinery.  A career which started in custom injection molding building a solid foundation in thermoplastic materials, processing, and tool design leading to an accomplished engineer specializing in high and low volume plastic product development.  Plastics experience which spans from injection molding of tight tolerance complex parts, helical gears, and insert molds.

                                                                            Core Competencies

Project Management                                                                                    TS16949/ISO13485

Product Testing & Evaluation                                                                      Pro-e

Injection Molding & Tooling                                                                        Pro-Mechanica  - FEA Analysis

Supplier Sourcing & Vendor Relations                                                    CF Design - CFD Analysis

Machine & Mechanism Design                                                                  SolidWorks

IQ, OQ, PQ Validation                                                                                   APQP - FMEA - DOE

Part & Assembly Cost Reductions                                                            GD&T

Project Status & Presentation                                                                    Six Sigma Green Belt

Work History

Work History
Aug 2012 - Present

Supplier Quality Lead Engineer

GE Healthcare

Supplier Quality Lead Engineer for a division of a major medical manufacturer of Radiology, X-ray, CT equipment and single use disposable products.  Part of a four person SQE team integrating the acquisition of Vital Signs Devices in compliance toGEHC purchasing controls procedures.

 uAuditing suppliersQMSfor compliance with ISO:9001, ISO:13485 standards, and FDA 21 

          CFR820 regulation

Oct 2009 - Aug 2012

Project Development Engineer

ProMed Molded Products

Project Engineer developing tight toleranced LIM, GIM, and Transfer molded silicone parts for the medical industry. Specialty in class VI implantable silicone and micromolding of thermoplastic engineering resins.  IQ, OQ, and PQ qualification of silicone molded parts.  Accomplishments in six sigma, capability studies, Gage R&R, and DOE's.

2008 - 2009

Sr. Project Engineer

Project Engineer/Applications Engineer for the development of filtration solutions for commercial OEM's.  Responsible for cost effective solutions in a highly competitive market.  Testing and evaluation of new media designs.  Release of new filter configurations per TS16949 requirements consisting of DVP&R's, DFMEA's, Gage R&R studies, and qualification runs meeting 1.66 Cpk acceptance criteria.  Customer sales and applications support.  Engineering responsibility for all differential pressure sensors and switches.

- Performed DOE on filter design variables to maximize performance with improved capacity, efficiency, and pressure drop over the competition on a potential $1M program

- Design Analysis and resign of differential pressure sensors reducing failures and saving $20-30K in field returns.

- Plastics consultant on material and design of Duramax2 cartridge filter design and other non-matallic filter componenets.

2005 - 2008

Project Engineer

Phillips and Temro Industries

Project Engineer and Project Manager in the development of custom engine intake, cooling system, oil, and cab heaters for commercial OEM's.  Conceptualization, prototyping, testing and final design of heaters per TS16949 requirements.  Project Manager leading cross functional teams following  APQP guidelines and procedures.

- Developed several specialized heaters, 120V and 240V, for improved cold starting performance.

- Developed several air intake heaters, 12V and 24V, for improved cold starting performance while reducing white smoke emissions.

- Developed a 12V & 24V heater for a major OEM with improved performance and reduced cost over the competition winning over $1.2M in new business.

- Solved a major field failure for Caterpillar maintaining a $20M account on an air intake heater and earning a patent on the redesign.

 - Developed an injection molded Pitot tube breather for a major OEM incorporating  PTC thermistors (heaters) saving further engine destruction at $30K per engine.

2002 - 2005

Project Engineer

Original Engineer and Project Manager in support of an acquisition and new product line start up for an injection molder, extruder, and manufacturer of high purity products that transport and protect critical materials for the semi-conductor industry.  Overseer of product design, project management, vendor sourcing, machine validation, and team coordination for the tape and reel product line.

- Managed the development of proprietary custom machinery for semiconductor and micro component packaging including vision system integration and machine design

- Successfully developed the concept, design and installation of the Pellet to Part thermoforming line bringing in 5M of new business within an aggressive 6 month schedule.

- Program Manager and hands-on engineer in the development of a ground breaking  tape-on-demand thermoforming system utilizing real time machine diagnosis and production data logging.

- Designed several secondary winders and rewinders for support of the "Tape on Demand" thermoforming system.

- Design and fabricaton of fixtures and test systems for support of the tape and reel line.

2001 - 2002

Sr. Project Mgr.

Senior Project Manager managing multiple customer accounts and tool builds in a classic cradle to grave environment for a custom injection molder of class 101 tools for the automotive, medical, and consumer product industries.  TS16949/ISO13485 certified molder.

- Managed the mold development process from order to production part approval process (PPAP).

- Controlled multiple project budgets, schedules, and the coordination of cross functional project teams

- Utilized scientific molding for process characterization and validation.

- Assisted customers in part design and material selection winning over new accounts and increasing sales by 5-10% with new and existing accounts.

-managed several high-profile projects with 15-20 active clients during a period of high department staff turn-over leading to unprecedented manufacturing restraints

1996 - 2001

Sr. Project Engineer - Plastics

Lead Engineer, Project Manager, and Plastics Engineer in the development of floor cleaning appliances for the consumer and industrial markets.  Plastics Engineer in support of internal and external tool builds and plastic part fabrication and procurement for injection molding and rotational molding.

- Engineering team member in the development of the 3200 36V rider scrubber.  Responsible for deck design including brush motor and deck lift mechanisms.

- Lead Engineer in the development of the 2800 24V rider scrubber.  Responsible for the industrial design and mechanical design of the chassis system including rotational molded tanks and electrical system integration.  Highest grossing machine in companies sales history with over $8M in first year sales and earning 3 patents.

- Lead Engineer in the development and industrial design of the Aquaspot 110V carpet spot extractor. 

- Plastics engineer in the design and development of injection molding and rotational molding tooling and molded part procurement. 

- Redesign of a diecast part to a molded part saving over $25.00 per part over diecast and machining.

1992 - 1996

Sr, Mechanical Engineer

Lead Mechanical Engineer and Supervisor in the development of medical test equipment, medical devices, and consumer products.  Plastics engineer in the development and procurement of tooling in support of product development.

- Design Engineer in the development of Starkey's ProConnect programming module consisting of mechanical design of electronic enclosures. 

- Design Engineer in the development of personal hand held remote controls for controlling hearing aid response generating $2.4M in new sales for the product line.

- Design Engineer in the development of Starkey new line of telephone headsets including control box and headset tops increasing Starkey's market share 20%.

- Managed over 30 injection molding tool builds and part qualifications.


1984 - 1986

St. Paul Technical Vocational Institute

Classes in Tool and Die Design and Tool and Die Mold Making




Tool Design and Development

Design and development of high precision class 101 tooling using H13, A2 and S7 tool steels.

Plastic Part Design

Design of molded parts for low cost, low maintenance, high accuracy tooling.  Design of snap together housings, insert molded parts, overmolded parts, and complex gearing.

IQ, OQ, PQ Validation

As related to injection molding and molding equipment.  OQ: Studying filing pattern of cavities, time studies of fill speeds, gate freeze studies, mold cavity balance studies, and determining process window. PQ: Qualifying the process from cold start as repeatable.

Vibration Analysis

Heavily involved in vibration testing for wear and durability.  Direct interpretation of results and authoring reports.


Use and interpretation of geometric dimensioning and tolerancing.  Went through certification program in 2008.

FEA Analysis

Pro-Mechanica non linear FEA analysis

CFD Analysis

CF Design - CFD software for air and fluid flow analysis

Pro- Engineer

Pro-Engineer design and development software.

Letters of Recommendation


2003 - Present

Six Sigma Green Belt