Robert D Gale

**** * ******** ** ****** AZ ***** 814-***-****) ad4yp5@r.postjobfree.com

This letter is to express interest in bringing my 30+ years of Mold Tool Engineering, Project Management, and new product development experience to your firm. Over the course of the last 40 years, I’ve developed my skills as an accomplished hands-on Mold Tooling engineer. I consider my key strength as working directly with product engineering to ensure peak mold process performance, with the lowest possible scrap percentage. If you take time to review some of the company web sites, I’ve provided in my work experience, you will see many of the products in which I have been directly involved with developing. In many cases these products still run high volume production today and are considered leader(s) in their industries.

I have principal level experience with “Reel to Reel” Molding, Rotary Insert molding for Aerospace, Military, and Automotive industries. I also have a well-rounded background in conventional/horizontal type molding high density tightly toleranced Telecom housings, as well as high cavity Medical, and Consumer industries.

In addition to the above skills and experience, I can also offer your firm:

●Hot Manifold development, direct, and valve gate. (Günter, Husky, Mold Masters)

●Extensive 2 shot molding experience.

●Dove Tail Collapsing Core Technology.

●Unscrewing (Unwinding) Rack, and servo drive.

●Extensive Pro-E, SolidWorks experience (allowing detailed mold design review, and clear communication with product engineering, as well as mold suppliers DFM).

●Moldflow, Mold-X 3D Melt Flipper.

●GOM Inspect Metrology CT/Blue Laser Scan Metrology.

●Volume Graphics CT Scanning technology. 3D Metrology, 3D GDT Surface Profile Tolerancing.

●High Speed Stamping Integration with Rotary Molding.

●SolidWorks 2022 MBD (Model Based Definition) 3D GDT.

●Automotive PPAP qualification process experience.

●Aerospace AS9100 qualification process experience.

●APQP deliverables and sign off.

In closing, I pride myself as being a highly motivated team-player, with a substantial history of successful programs to show for it.

Thank you for your consideration.

Upon request creditable references from each of these former employees can be forwarded.

Eaton Aerospace (Paso Robles CA) www.eaton.com 2021 Current

Sr. Development Engineer New Product Launch

As New Product Development Tooling Engineer, I wrote the justification to replace over 30 legacy molds with new production class 101 molds which produced parts for Boeing and Airbus, resulting in an approved budget for 1.4M with a 2.5-year ROI. Designed/developed/deployed quick change face mount mold base system standard, reducing changeover time from 6hrs to 20min for low volume part numbers.

To reduce development lead times, I worked with purchasing to onboard 8 new mold suppliers to work in parallel on the 30 new molds. All working to a common standard to insure fitment with Eaton internal molding systems. Onboarded a CT Scanning company leveraging in parallel FAI template creation greatly reducing FAI report Leadtime to within 24hrs of receiving T1 part samples. Also used CT technology report data to ensure customers parts from the new molds matched the legacy parts, thus “0” risk for them. Trained and deployed GOM Inspect 3D GDT principles with the internal quality team, created digital FAIs per aerospace AS9100 standards.

Worked directly with Product Engineering for DFM optimization. Eliminated thin steel conditions, opened thin wall section for improved fill confidence. Datum creation, optimize true position call outs. Stack Tolerance analysis reviews. Also worked with product engineering to cross train for MBD (Model Base Definition) to output 3D pdf files increasing product drawing efficiency by 5X over traditional 2D product drawings as well as leverage Surface Profile 3D GDT annotations thus greatly reducing the number of print dimensions.

Responsibilities:

Write budget justification with 2.5-year ROI minimum.

Manage-Mentor 15-man Mexico Internal tool shop mold maintenance best practices.

Cross train Product Engineers to use 3D CT scans GOM Inspect.

Review – approved mold designs to insure best tool performance, and longevity.

Work with Mexico Sustaining Tooling engineers to resolve on going issues with older molds.

DFM through concept mold design during the product design phase.

Work with cross functional project managers to ensure samples were delivered globally on time.

Work with Product managers (marketing) on capital investment strategy based on EAU forecasts.

Concepted quick change “face-mount” standard mold base platform for low volume part numbers.

Onboarded 8 new mold build suppliers to support reverse engineering and building new 101 molds.

Travel to production sites to align their capabilities with the tool development plan.

Implemented drafting standards ANSI Y14, numbering system for molds and tooling.

Work with Mexico Mold operations with problematic Unscrewing, Dove Tail Collapsing core issues.

Managing 5 suppliers working in parallel to build 30 new production class 101 molds.

Coached new Product Engineers on CT scan – Volume Graphics evaluation. Review internal Voxels of CT scans for 8D root cause defect reports for Boeing and Airbus torque test failures.

Implement 27p 53p RJG master molders scientific mold approval process prior to FAI.

TE Connectivity (Winston Salem NC). www.te.com 2018-2021

Sr. Development Engineer New Product Launch (ICT BU)

As new product development engineer, I launched several new products to TE customers with minimal supervision from my peers. It was critical these products be launched and not distract the already overloaded mold engineering team. In addition, lend aid to peers with projects they were struggling with globally.

Responsibilities:

Provide DFM feedback to product engineering for optimal performance for long term manufacturing.

MoldX 3D Flow studies to identify problematic issues with product design.

Review – approved mold designs to insure best tool performance, and longevity.

Project managed offshore supply base to meet committed delivery schedule.

Qualify FAI inspection via CT scans using Volume Graphics (3D metrology)

Work with cross functional project managers to ensure proto samples were delivered globally on time.

Work with Product managers (marketing) on capital investment strategy based on EAU forecasts.

Implement quick turn mold standards to improve time to market, also support long term production.

Global travel to resolve critical path tooling issues as directed by upper-level management.

Travel to production sites to align their capabilities with the tool development plan.

Project managed 30 new mold build projects in parallel.

Implement quick turn prototyping, with designed in options to allow conversion to class 102 mold.

OCS LLC (Subsidiary of LNG Malaysia). www.lng-res.com 2016-2018

New Business North America Technical Sales Manager Tooling Sales Manager

As Operations Manager I set up a new sales business unit “OCS LLC” in compliance with US Federal and NC state laws. New business development and new customer sales, and customer support. Sales calls and sales presentations with new customers. Accomplished 800k in sales within final 3/4’s of 2017, on pace 4M for 2018.

Responsibilities:

●Create Sales/Business strategy to win new customers in Aerospace, Automotive, and Military markets.

●Work with customer product Engineers for DFM, (goal to win right of refusal on RFQ’s)

●Project manage multiple molds being developed and qualified in parallel.

●Mentor Manage the Mold, Die Engineering teams in Malaysia (difficult insert mold concepts).

●Managed Insert molded projects between multiple sites (stamping, plating, molding different sites).

●Principal Engineer in development of “Reel to Reel” and Rotary molds for Tesla, Chrysler, Fiord

●Quoting Molds, Dies, Insert Molds, Turned and Milled Machined parts.

●Managing PL and BU margins to achieve the best possible margins.

●Mold Design concept on some of the more difficult mold projects (Creo -3 and SolidWorks’).

●National and International sales travel to business development.

●Work with internal molding group to resolve PPAP, Cmk and other qualification issues.

●Mold Flow MPI/MPA Studies for customer DFM’s (sales value add).

●Manage business unit invoicing, procurement with Asia partners, customer debt collection.

●Investigated and trained the Engineering team on “Blue Laser/CT scan” metrology using GOM software.

FCI International Harrisburg PA. www.fci.com 2014-2016

Sr Mold Development Engineering Manager, Molding / Insert Molding

As senior mold process engineer, I worked closely with product engineering to ensure design for manufacturing. In some cases, design alternative concepts. I am responsible for FMEA, and PFMEA prior to tooling launch. Was directly involved with the quality team, and approved inspection plans, fixtures, gage R&R evaluation.

Once approved for release I was responsible for Injection mold and Insert mold tooling design reviews prior to release for fabrication, project management through qualification pass with both domestic and Asian supply chain. Once qualified, I was responsible for transfer and qualification at our internal site in Southeast Asia.

Responsibilities:

Manage a team of 5 Tooling Engineers with 60 Molds in various stages of development.

●Preliminary design splits/concept, thus providing product design feedback prior to RFQ release.

●Mentor – Manage priorities, and development of the two engineers that report to me.

●Archiving mold tooling drawings within Windchill for global access.

●Work in parallel with product engineering to ensure DFM (design for manufacturing).

●Mold design in parallel with product design via Windchill (fast track time to market).

●Maintain global mold base design standards.

●Transfer training from the new build team to the operations team.

●Work with purchasing department to evaluate-develop-qualify Asian, and domestic suppliers.

●Support continues process improvements with the operations team in Southeast Asia.

●Estimate mold cost, cycle time, entitlement (utilities).

●Moldflow, Mold X 3D 2011, run studies, review confidence of fill, pressures, core deflection etc.

●Project Manage Asian suppliers, build and transfer.

●Trouble shoot molding issues both internal and external operations teams.

Amphenol-TCS Winston Salem N.C. www.tcs.teradyne.com 2007-2014

Sr Mold Engineer / Advanced New Product Development

As senior mold engineer, I’ve successfully worked with the operations team to build an engineering team to design, build, and qualify complex, high cavitation production class insert molds. I’m considered the principle insert mold design engineering resource, responsible for review, and approving product designs prior to their release.

Responsibilities:

Manage designs and qualify designs of over 80 8-16 Cavity “Reel to Reel” Insert Molds.

Establish internal standards maximizing flexibility across the molding floor.

Direct internal and external mold design resources. Held internal design reviews.

Work in parallel with product engineering to ensure DFM (design for manufacturing).

Mold design in parallel with product design via Pro-E Windchill (fast track time to market).

Train Asian design team in best practices, and global drafting and format standards

Direct internal build team, report program progress to management.

Transfer training from the new build team to the operations team.

Work with operations to retro fit, mold transfers to meet internal standards.

Support sustaining process improvements with the operations team.

Explore and develop Hot Manifold systems (Mold Masters, Günter, and Husky).

Estimate mold cost, cycle time, entitlement (utilities/yield).

Moldflow MPI 2011, run studies, reviews confidence of fill, pressures, core deflection etc.

Project Manage Asian suppliers, Mold build and transfers to meet internal standards.

Precision Concepts Group LLC Winston Salem N.C. www.precisionconcepts.com 2002-2007

Mold Engineering Manager / Technical Sales

As Mold Engineering manager, I interfaced directly with the customers concerning new product development, as well as current production quality related issues. I also made sales calls, with our sales manager, hosted customer presentations to review process flow, and review design intent. These customer calls resulted in winning several medical, automotive, and telecom insert molded programs.

Responsibilities:

●Estimate mold cost and lead time, cycle times, and utilities.

●Sales calls with national sales manager for technical sales (DFM inputs)

●Concept process flow for complex insert molding product designs.

●Manager of internal tool mold maintenance, tool room.

●Project Manage external suppler mold design and build.

●Develop mold standards to reduce, cost lead-time, and ensure minimal error on future builds.

●Moldflow studies using Moldflow MPI 6.2 (ensure fill of thin wall parts)

●Design concept the more difficult molds (hydraulic side actions, Hot Manifolds)

●Mold Automation interface mis-feed detection.

●Developed prototype mold base units (Drive lowest tool cost, with goal of production mold win)

Berg Electronics (FCI) Harrisburg P.A. www.fci.com 1996-2002

Sr. Mold Design Eng. / NPI Team Member

As Sr. Mold design engineer, I worked directly with product engineering to ensure product design intent included design for manufacturing best practice principles. In this position the product engineering team and I launched over 50 fast track time to market products, most of which are still in high volume production today.

Responsibilities:

●Concept Mold Designs, work with the drafting team to complete the Mold Design.

●Principal “Reel to Reel’ and Rotary Insert Molding Engineer.

●Manage 2 man drafting team ensuring standard ISO drafting practices were followed.

●Projects manage component build, ensure all component details meet workmanship standards, and come in per schedule.

●Review and provide feedback of all new products to ensure design for manufacturing.

●Review FAI data, groom Molds to FAI pass results. (cpk 1.67)

●Project Manage external design and build of Mold.

●Manage mold transfer from suppliers to internal operations team. Also gage R&R, Inspection req.

●Developed international design standards, making international mold transfers less costly.

●Team leader of internal Tool Room to support “quick turn” time to market projects.

Chenango Tool Inc. Chenango County N.Y. 1979-1996

Mold Tool Maker

Started apprenticeship summer of 1979. Squaring machining cavity blocks. Apprenticed Mold Building through 1986, earned Journeyman status. As Journeyman Mold Maker responsibilities included, complete mold build, from squaring cavity blocks, Heat Treatment, completing machine detail work on cavities, and machining and installing the cavities into the Mold Base. As Journeyman Mold Maker I was proficient with, and used best practices for EDM, Wire EDM, NC EDM, CNC Milling, Surface Grind, and polish to SPI-SPE A-3 finishes.

As Mold Maker I was responsible for successfully project managing and building over 135 production class molds for the Automotive, Medical, Firearms, Consumer goods industries through use of all machining practices mentioned above. In 1990 I took vocational night courses for AutoCAD release 9, and started mold design from home, then later in the internal office.

Proficient with the following software.

Pro-E 2001 through Wildfire 5

Pro- Creo (Windchill)

PTC Intralink 3.1 (PDA)

Solidworks 97 through 2023 MBD Process

Moldfow MPI 6.2 through 2011

MoldeX 3D Flow Software

Volumw Graphics VG Studio MX

Zeiss (GOM Inspect)

MS Excel

MS Power Point

MS Project

MS Word

Experience with the following resins.

LCP (most engineering grades)

Nylons (most engineering grades, including some 40% carbon fiber)

Polycarbonates (medical, commercial)

Peak

PBT

Fortron

Rynite

Ultem

Education / Training.

High School diploma: Sherburne Earlville Central School Sherburne NY.

NYS Apprenticeship (associate degree)

BOES; advanced machining.

Vocational AutoCAD R9-R14

PTC (Pro-E) Fundamental (foundation)

PTC Advanced modeling and Assemblies.

Rand Advanced Assemblies for Pro-E 2001

Rand Advanced Assemblies Intralink 2.1

Cadquest Advanced Mold Design Assemblies

Trimec Solidwoks Part Design 2008

Trimec Solidworks Advanced Assembly 2008

Trimec Solidworks Drawings 2008

MoldFlow Insight Performance 6.2

MoldFlow Insight Standard 2 6.2

Mudflow Insight 20015

MoldeX 3D Software Training

Principal molding engineer responsible for bringing to following product lines to market.

FCI Meg Array

https://www.digikey.com/en/product-highlight/f/fci/meg-array-connector

FCI Gig Array

https://www.amphenol-cs.com/product-series/gig-array.html

Amphenol Xcede

https://www.amphenol-cs.com/product-series/xcede.html

Amphenol Xcede HD

Contact this candidate