Summary
Manufacturing Engineer II with 13 years of experience in the Aerospace Industry. I have a long history of driving process improvements throughout manufacturing. These improvements have included everything from small technique changes to major process and equipment changes. As a result, I have become the central figure in processing improvements.
Accomplishments
Chemical Etch
• Developed and implemented Airbus Heated Floor Panel heating element resistance etch machine and created etch rate algorithm. Improved yield from 75% to 98%.
• Performed Design of Experiments to optimize parameters to reduce thru etch scrap by 5%.
• Corrected resist adhesion problems on copper products related to light intensity and implemented permanent solution.
• Implemented new resist developer machine with improved chemistry control. Reduced pinhole scrap by 25%.
• Implemented new personal protective equipment in the etch room.
• Implemented AgustaWestland leading edge heating elements into production.
• Maintained engineering support for timers department while driving yield improvements in the etch area for a nine month period.
• Flowed heavy maintenance of wet processing equipment to vendors.
• Implemented one piece artwork for AgustaWestland heated leading edges to reduce scrap by 30%.
• Defined acceptance criteria for Heated Floor Panel elements.
• Developed a system to replace photo-tooling on a usage basis.
• Driving lamination improvements to reduce defects due to foreign material at exposure process, expected yield improvement of 5% over existing.
• Implementing new “Steel Etch” production line with improved controls. Expected reduction in over processing by 25%.
• Disposition(ed) non-conforming material.
• Implementing thicker resist on elements to reduce thru etch defects. Expected reduction in defects of 10%.
• Implemented scheduled DI water system maintenance to improve consistency in rinsing of etched elements.
Heated Composites
• Eliminated wrinkles in Airbus Heated Floor Panel elements to eliminate 60% scrap rate.
• Reinvented hole punch method on Heated Floor Panel elements from square punch to round punch to eliminate tearing of elements caused by punches.
• Improved Airbus Floor Panel element alignment to a hole and crosshair system that improved yield from 75% to 99%.
• Reduced testing time for Boeing Heated Floor Panel Heat Testing from 1-hour, 45 minutes to 45 minutes before production implementation.
• Corrected Beech Leading Edge watt density to improve yield.
• Implemented Boeing Heated Floor Panels, Augusta leading edge heating elements, Gulfstream Water Heater and Heated Hoses into production.
• Maintained engineering support for timers department while driving yield improvements in the heated composites for a six month period.
• Implemented two walk in heated air ovens into production.
• Tightened tolerance on heated floor panel elements to eliminate high resistance at final assembly.
• Implemented pretesting of Boeing Heated Floor panels to eliminate scrap controller issue.
• Performed infrared testing of First Article Airbus Heated Floor panels to eliminate shipping damage.
• Removed unnecessary hour long bake of Floor Panel heated elements before solder.
• Disposition(ed) non-conformi...
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