PROFILE
Manufacturing Engineer with over 10 years of demonstrated expertise in process development, new product launch, capacity growth, and quality improvement. Strong interpersonal, organizational, analytical, and problem-solving skills with a focus on implementing of cost-effective solutions to facilitate lean manufacture at the quality level and cycle time required. Generated significant cost savings through expertise in:
* Six Sigma DMAIC - Black Belt Certified
* Statistical & Graphical Data Analysis
* New Product Introduction & Validation
* DOE, Gage R&R, SPC, Control Plan, FMEA
* Class 100K Clean Room Operations
* Laser Processing & Monitoring Systems
* Outsourcing & Capacity Growth
* Quality Management System - GMP, FDA, ISO
* Equipment Selection & Qualification
* Project Management
PROFESSIONAL EXPERIENCE
SENSATA TECHNOLOGIES INC. (Formerly Texas Instruments Inc.), Attleboro, MA 2006 - 2008
Manufacturing Process Engineer OWS & MSG, Sensors & Controls Automotive Group
A key member of the Global New Product Development Team throughout entire process cycle (from design concept, validation, launch, transfer, ramp up, and sustain).
* Developed robust laser weld processes for hermetic and structural applications in multi million dollar Occupant Weight Sensor (OWS) & Brake Pressure Transducer (BPT/MSG) automotive business.
* Conducted series of extensive experiments (DOE) to develop enhanced laser welding profiles implemented for re-processing of approximately 65K safety critical OWS devices. Generated cost saving of approximately $2M.
* Evaluated and qualified advanced laser process monitoring system, enabling none destructive, real time product inspection and data collection. Reduced statistical process control (SPC) frequency by implementing the system in Sensata, Malaysia (STM) production, resulting in cost saving of approximately $45K per year.
* Developed several friction weld processes to accommodate force element assemblies (FEA) of safety critical sensors. Transferred two MTI friction welders and ADMET SPC tester to components supplier located in Thailand - Generated cost saving in excess of $125K per year.
* Evaluated and qualified an alternative 17-4 stainless steel supplier of FEA components. Generated cost savings of approximately $75K per year.
* Performed capacity analysis and planning for effective asset utilization and expansion of OWS production. Increased capacity by 12.5% to 7.5M units per year.
* Created new equipment capital authorization requests for OWS Expansion II. Presented to management, received approval for equipment design and fabrication ($2M). Generated machine specifications, qualification plans, process controls, and training documentation.
* Qualified and transferred a Final Assembly Machine ($1M) to STM. Achieved pre-transfer machine capability of GRR1.67, and first time yield >95% for the most critical stations.
TEXAS INSTRUMENTS INC., Attleboro, MA 2000 - 2006
Manufacturing Process Engineer APT, OWS and MSG, Sensors & Controls Automotive Group
Facilitated successful new product introduction by utilizing advanced quality planning methods (FMEA, Flow Charts, Control Plans, etc.) to predict problem process areas and implement countermeasures. Provided training & support to engineering and operations of make sites.
* Facilitated successful launch of 17 MSG devices by utilizing Six Sigma Methodology and applying documented lessons learned from previous NPD programs.
* Worked with design engineering team in validating and process development activities for new and existing BPT sensor opportunities. Realized 4% incremental cost reductions and capacity output metrics prior to production release.
* Provided manufacturing engineering support to APT Cell 2&3. Launched 14 new APT devices. Conducted several capability studies and DOEs of leak testing and crimping equipment. Initiated manufacturing Cell 2&3 transfer to make site Sensata, Mexico.
* Collaborated with suppliers and contract manufacturers to insure processes are capable, have sufficient controls in place, can meet delivery requirements and cost targets.
TEXAS INSTRUMENTS INC., Attleboro, MA 1996 - 2000
Manufacturing Engineering Technician MSG, Sensors & Control Division, Automotive Group
Utilized and maintained industrial laser processing systems (Rofin CO2, GSI Lumonics MW Nd:Yag), friction welding (MTI), and wire bond (Delvotec) equipment in cost of over $2M for developing, and prototyping of several sensor platforms within Clean Room Class 100K environment.
* Assisted in debug and qualification of new assembly and test equipment for OWS & MSG sample and manufacturing lines. Performed several equipment capability studies.
* Conducted over hundred DOEs to develop laser parameter settings for edge joint seam and spot welding of stai...
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