Professional Experience
Senior Product Development Engineer, Tyco/Scott Health & Safety. May, 2005 - Oct. 2009
Responsible for cradle to grave product development, planning, testing, and production launch. Product lines include fire fighter facemasks; thermal imaging cameras; chemical-biological-radiological-nuclear filtration devices; personal alert safety systems; and powered air purification respirators
• Manage product development activities to minimize time to production launch
• Report progress and communicate diligently and effectively to support the decision making process as milestones and development gates approach
• Support manufacturing floor by developing and testing equipment, conducting line worker time studies and injury prevention/elimination studies, and error proofing by design
• Plan, perform, analyze, and report on Voice of the Customer questionnaires and surveys
• Aid in creation of budgets and timelines for projects
• Perform CAD modeling, prototyping, experiment design and validation testing
• Design tests and experiments using 6 sigma principles and statistics to analyze data
• Ensure design compliance with NFPA, OSHA, ISO, & NIOSH standards
• Collaborate with multi-functional and global product development teams
• Assist in supplier development and quoting process
• Perform root cause analysis and Corrective Action Resolutions on existing products and prototypes
• Write engineering reports and maintain historical records and lessons learned files
• Member of excellence team responsible for improving work flow and establishing best practices
• Increased company market share with design of first to market technology protecting first responders in multiple threat environments with Top-Down-Convertible face mask
• Benchmark competitor products and review patents to avoid infringement issues with new designs
• Patent holder: face mask sealing land design (US 2010/0258131)
Product Engineer, SSI Technologies. October, 2001 - May, 2005
Responsible for concept to completion program management, development, testing, and production launch of automotive and recreational vehicle sensors and components including injection molded housings, o-rings, cables, fasteners, sealants, magnets, coil wire, probes, terminals, and connectors
• Evaluate customer needs and establish appropriate documentation, design and test specifications
• Create and maintain documents to meet ISO standards: DFMEA, DVP&R, SPI, PFMEA, and DFM
• Analyze total program costs and timing and present to upper management and customers
• Select suppliers and tool makers and direct their activities to optimize cost, timing, and quality
• Manage prototype builds for testing and on time delivery to customers
• Execute DVP&R and PPAP testing according to internal, SAE, and customer specifications
• Perform test set-up, data collection, analysis of data, and report on results to the customer, implement design corrections as needed based on test results
• Implement design and production improvements to decrease scrap, rework, and cycle time
• Support production floor to improve design for manufacturability, and to implement cost savings
• Perform root cause analysis and problem resolution activities of field failures and customer returns
Development Engineer, Sachs Automotive. June, 1996 - October, 2001
Responsible for the development and testing of strut modules and their components including twin tube shock absorbers with passive, semi-active, and continuously variable damping capability; polyurethane jounce bumpers; rubber mounts and bushings; brackets; coil springs; air springs; and o-rings.
• Tune shock absorbers to meet customer ride, handling, and durability requirements
• Develop test specifications and fixtures based on road load data and vehicle configurations for accurate laboratory sub-system and component level testing
• Provide full support to laboratory and durability vehicle testing including writing Supplier Engineering Reports, resolving test incidents, and implementing design changes
• Interface with suppliers to improve product performance and design robustness
• Manage proto-type builds and deliveries to OEMs with aggressive timing
• Provide on-site resolution of assembly, quality, or design issues at the OEM and assembly plants
• Implement design and assembly improvements to decrease scrap, rework, and cycle time
• Act as technical support and German translator to facilitate communication and understanding of new te...
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