Corporate Management, Business Analyst, Strategic Planning, or other positions requiring investigation, analysis and leadership to effect continuous cost effective improvements of the company, people and products. Prefer a start up environment free of entrenched thinking.

PROFESSIONAL PROFILE:

• Developed team environment and coordinated simultaneous engineering with all functional areas, reducing time to market by 50% over other previous product entries.
• Designed and specified special manufacturing fixtures resulting in 100% gain of throughput.
• Identified hidden factory, which was 20 times the actual scrap being reported. Presented compelling business case for changes and evolution of WIP labor and scrap reporting. Attention on true costs brought about accountability and resolution resulting in millions saved.
• Implemented SMT component assembly, hot air and laser production line soldering process.
• Identified and resolved critical reliability problems such lead to hole ratio for out-gassing of wave soldering and shock sensitive modules and intermittent connector problems.
• Developed alignment fixture and datum controls for 100% simultaneous plugging of 96 connectors eliminating plugging problems and crushed connectors.
• Discovered phase change of certain solder alloys that resulted in brittle solder joints. Resolved alloy and manufacturing issues to minimize use of re-flow solder ovens.
• Analyzed and resolved multi-layer circuit board delamination and board crazing problems with plasma etch and process control of materials resulting in 40% increase of acceptable board output. Drafted a white paper on this subject and other improvement topics.
• Coordinated shop floor control and work cell scheduling to achieve continuous flow manufacturing eliminating 90% of floor space used in staging areas or about 15% of total manufacturing space. This also reduced handling damage and gained related cost efficiencies and reduced customer returns and complaints by over 90% resulting in significant savings that directly went to improvement of the bottom line profits.
• Developed solutions and rapid response to complex manufacturing and QA problems by innovation, vision, coordinating team skills and application of engineering principles.
• Gained positive team reputation with fellow employees, management, suppliers and customers for being resourceful, fair, objective, solid engineering competence, accurate risk assessments and for initiating comprehensive corrective actions.
• Established PDM (product data management) to track component parts and monitor part lot failure PPM levels in the field to base product recall determinations or schedule component changes during scheduled maintenance intervals of critical systems.
• Established project milestones, monitored adherence to master plans, schedules, identify bottlenecks and obtain resolution by creative allocation of resources or negotiated changes.
• Supervised special work teams, manpower and contract employees for special tasks required to respond to meet delivery schedules and contract obligations. Scheduled work and overtime needed and provided instructions for the non-scheduled work to be performed.
• Tracked program costs reporting WIP status to accurately reflect actual value-added cost.
• Interviewed and selected new employees, conducted training, performance reviews, salary negotiations, work assignments, and documented employee disciplinary actions as needed.
• Extensive manufacturing industry knowledge base, aerospace, aircraft, machining, composite materials, thermal processing, injection molding, bonded assemblies, electrical and electronic connectors, circuit board fabrication, chip manufacturing, clean room procedures, and automation pick and place systems.

QA and Reliability

• Worked with Dr. Edwards Deming on continuous improvement projects and seminars.
• Provided leadership in procurement quality assurance. Established criteria and basis for supplier certification and dock-to-stock (DTS) parts eliminating 80% of inspection functions allowing transition of inspectors to in-process inspection, calibration and focus on preventative and corrective actions.
• Developed metrics on supplier quality, delivery performance ratings and ISO 9000 audits.
• Established MRB function and coordinated with functional areas QA, Engineering, Purchasing, Manufacturing and inventory. Developed a system to learn from mistakes internally allowing anyone on the manufacturing floor to flag a suspect part for evaluation, and to provide for external supplier feedback with a corrective action follow-up systems.
• Gained confidence and trust by all functional areas on my engineering judgment and balanced risk assessments and was designated primary authority on stop orders and methods of resolution for over 3,000 manufacturing employees. Provided decisive leadership coordinating and seeking input of other functional areas where needed.
• Developed revised and maintained QA instructions and manufacturing instructions or process controls with hands on work to eliminate or reduce process variables moving process capability from 3 sigma to 6 sigma.
• Upgraded capability of receiving inspection department, specified inspection equipment including coordinate measuring systems, optical gauging, supervised acceptance sampling testing, hired, trained and provided technical support in the use of measuring techniques.
• Certified inspection staff for measurement accuracy and repeatability and provided training on geometric dimensioning and tolerance (GDT) print reading.
• Designed and specified go/no-go gages utilizing GDT and worse-case tolerance stack evaluations for QA and manufacturing applications resulting greater accuracy and throughput eliminating part assembly problems and the associated costs.
• Established failure analysis labs, specified and acquired equipment for part qualification, acceptance testing, and hired, trained and provided on-going supervision and guidance on complex issues.
• Hands on cross-sectioning failure analysis, knowledgeable in metallurgy, solder and plating alloys, metal fatigue and conducting penetrating dye fracture inspections.
• Conducted extensive investigations determining root cause failure analysis and establishing rapid response corrective actions. Liaison providing technical findings, reports and presentations to all functional areas and affected suppliers and customers.
• Established calibration lab, designed or specified equipment, hired, trained and gave technical leadership on complex calibration issues and calibration frequency schedule.
• Established certification of manufacturing processes and certification and testing of employees for electrostatic discharge and other critical manufacturing operations.
• Establish part qualification plans and identified inappropriate materials specifications, drafting dozens of ECO's that improved reliability and or profitability.
• Developed accelerated life and advanced qualification testing of component parts and sub assemblies with X, Y & Z axis shaker table and other non-destructive and destructive testing and failure analysis. Researched and specified needed equipment and then trained and provided technical guidance to operators for this added analysis capability.
• Developed SPC manufacturing controls, collected and analyzed process data, produced control charts and pareto charts to monitor continuous improvement activity. Monitored negative trends and out of control SPC conditions. Established effective use of pareto charts on manufacturing floor and the empowerment of production line staff to see improvements.
• Established engineering bar code standards - implementing in manufacturing and inventory.
• Automated data collection, MIS and product traceably down to component part lots for monitoring acceptable part per million (PPM) failure and risk priority number (RPN).
• Identified alloy problems, thermal transfer and thermodynamic coupling problems, lowering operating temperatures and doubling reliability and MTBF of electronic parts and systems.
• Directed use of gas spectrometry and electron microscopy to identify process contaminants.
• Established and acquired photography capability for manufacturing process documentation and communication of problems with management, suppliers and customers.
• Established thermal, power and vibration cycling of electronic components and the PPM lot acceptance criteria.
• Trained other employees on problem solving, TQM, SPC and ISO-9000 auditing. Facilitated employee continuous improvement efforts, participation and employee recognition.
• Developed employee suggestion system and value analysis for objective response/decision.

• International travel in conjunction with customer support and supplier improvement.
• Designed, manufactured and installed electronic alarm systems and UL central stations.
• General building contractor, proficiency with construction trades and project supervision.
• Served on board of directors for Elk Lake Rehabilitation community service project.
• FAA commercial pilot license and flight instructor - trained 6 other pilots to private rating.
• Provide school assembly demonstrations on math, physics, engineering and aviation.
• Extensive customer interface, contract negotiations and experience in union shops.
• ERP & MRP project manager on manufacturing plant implementations and data migration.
• Assisted in software design requirements and QA of software performance functionality.
• Developed custom software applications and specific programming algorithms.
• Broad computer proficiency, UNIX, HTML. XML, SQL, Java Script, Microsoft Project, Access, Word, Excel, Power Point and Internet e-commerce and Internet marketing.
• Knowledgeable on patents, intellectual property law and claim drafting with special interest to help inventors commercialize their inventions and spin off new companies.
• Proven ability to provide decisive leadership with high interpersonal and team skills.
• Senior member Society of Manufacturing Engineers (SME)
• Built a car from scratch that is now in a midwest auto museum. The car won 3rd place at the Chicago Auto Show and was voted the most popular car at other car shows.

BSIE Extensive continued education records available upon request.