-present Engineering Consultant: Assist clients with a wide variety of engineering challenges. Help them expand their engineering capabilities and improve their engineering and manufacturing processes and organizations. Projects include: 1) Design and fabrication of custom automated equipment. 2) LabVIEW programming. 3) Development of data acquisition systems. 4) Fixture, tool and process design. 5) Product and process cost reduction. 6) Cost and process modeling and analysis. 7) Product and process reliability improvements. 8) Project and operations management.
8/95 - 8/96 Varian Ion Implant Systems,Gloucester, MA
Value Engineer: Short term individual contributor position with the focus of reducing the cost of Varian's ion implanters. Completed approximately a dozen redesigns with combined annual savings of more than $2 million. Projects included a complete redesign of an electro-mechanical subassembly which reduced the cost of the subassembly by 60% and saved over $1 million per year. Other projects included converting machined parts to castings (aluminum sand castings and aluminum and stainless steel investment castings), respecifying vacuum pumps and vacuum systems to remove unnecessary features, and using a powder metal process to make refractory metal parts (a new fabrication process for Varian). Individual part cost reductions ranged from 10% to 80% with annual savings ranging from $60K to $400K per project. Used Autocad version 12, 2D drafting software and SDRC I-DEAS Master Series 3D solids modeling software.
11/94 - 8/95 Exergen Corporation,Newton, MA
Manufacturing Engineering Manager/Engineering Manager: Company of 40 to 50 employees designing and manufacturing infrared temperature instrumentation for the medical and industrial markets. Supervised three engineers, one draftsman, two contract engineers, and the quality department. Established the quality department and give direction for the installation of a quality system. Personally introduced two new medical products to manufacturing: finalized designs, completed procedures, resolved performance problems, coordinated prototype builds, and managed prototype inventory. Defined sensor testing protocols to meet the requirements of a large Japanese industrial OEM customer. Rationalized procedures in the industrial sensor manufacturing operation.
1/91-1/94 Ciba Corning Diagnostics Corporation, Medfield, MA
Systems Engineering Supervisor: Supervised four engineers and two technicians. Our first responsibility was to provide technical support to the mechanical and electronic assembly departments of the blood gas instrument operations. We solved assembly and instrument operational problems, resolved incoming quality issues, analyzed make vs. buy decisions, designed tools and fixtures, lead process improvement teams, and operated within FDA's GMP guidelines. We also performed product redesigns for performance enhancement and cost reduction, evaluated vendors for certification, provided manufacturability input to new product designs, and were responsible for introducing new designs into production. Performed individual engineering tasks in the areas listed as well as supervisory duties.
Shifted focus of group from 80% "fire fighting" and 20% project work to 20% "fire fighting", 60% new product design for manufacturability, and 20% project work .
Received an R&D Excellence Award for contributions to instrument introduction (managed timely resolution of technical issues between release to manufacturing and release to the market).
Member of Technical Challenge Team chartered with translating user requirements into feasible technical options for a new family of instrumentation.
9/89-6/90 Stanford University, Mechanical Engineering Department, Stanford, CA
Student Machine Shop Teaching Assistant: Taught structured labs in machining, welding, and casting. Provided design and fabrication guidance for student projects. Performed prototype fabrication and design services for research labs and sponsored student projects, using both conventional and CNC equipment.
6/89-9/89 Raychem Corporation, Thermofit Division, Menlo Park, CA
Cycle Time Project: Part of a team that analyzed plant cycle time and developed tools to track and guide cycle time improvements. Studied the two major bottlenecks in the operation and recommended a series of technical and procedural improvements to ease the bottlenecks and improve cycle time.
9/85-8/86 Plating Manager: Managed a department of 16 including a waste treatment
technician, process chemist, plating engineer, and production planner. The department delivered approximately 6 million gold plated connector pins to assembly each week. We were also responsible for gold scrap recovery, treatment of plating waste, and handling of hazardous waste for the entire facility. Implemented process improvements and developed new production equipment that reduced gold usage 10% through the reduction of process variability.
3/84-9/85 Manufacturing Engineer: Major areas of responsibility were quality
and production issues in the Plating Department, regulatory compliance in Waste Treatment, and the development and implementation of a Worker's Right to Know Program.