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Engineer Quality

3873, United States
March 22, 2011

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* ****** ****

Sandown, New Hampshire 03873



Presently; Consulting Engineer to Bodkin Design & Engineering, and R. D.

Webb Co. For system testing and data reduction; technical writing, quality

program support, and mechanical design; manufacturing, and process

engineering support. Bodkin designs and builds innovative optical systems

with contracts from MDA and AFRL regarding missile defense systems. Webb

designs and builds laboratory vacuum furnaces.

I have consulted with Bodkin Design to contribute to the design, build and

test of infrared hyperspectral imaging systems. This includes sourcing

optics and infrared imagers, inspecting the optics for quality with regard

to dimensions, finish, scratch/dig, (MIL-PRF-13830B) and vendor-supplied

interferogram. I assemble prototypes, align the optics, test the sub-

systems, report on the results and work with vendors/suppliers to solve

quality issues. I also worked with the software consultants to design and

test the complex image processing software to make the hyperspectral

imagers function. I also contributed to the design and build of other

projects including a mini-infrared zoom imager for UAV's. In all cases I

contribute to the periodic reports that are required and have contact with

customers, vendors and other consultants. For RD Webb I support the build

and delivery of laboratory furnaces and provide customer quality support on

installation and operation issues as they arise.

7/2007 to 7/2009; Insight Technology Incorporated, Senior Quality Systems


Responsible for product documentation and product test regarding contract

requirements. This entailed writing quality validation plans and test

procedures based on MIL-STD-810G, ISO:9001, referenced standards, and the

Product Performance Specification. Performed product safety analysis and

produced the Safety Assessment Report. I authored, reviewed, and approved

manufacturing work instructions. Performed root cause failure analysis and

directed corrective action for design and test discrepancies. I designed

and wrote the test plans for periodic testing and reliability and directed

the testing of LWIR (thermal) weapon sights and hand-held imagers. I

specified and directed the design of alignment stations for stand-alone and

clip-on sights. I was the principal quality engineer for the AN/PVS24A

night vision (I2) clip-on weapon sight. Solar radiation testing became a

requirement for all new weapon sights. I led the design of an in-house

solar radiation testing facility. I developed a field alignment station for

the Marines that will be used to maintain the AN/PVS24A. I worked with the

manufacturing engineers to develop a production test to incorporate spatial

noise and image uniformity testing to validate performance after production

calibration of uncooled microbolometer imagers.

I wrote the Product Assurance sections in the technical volume and SOW

(Statement of Work) for proposals. I reviewed and revised internal product

performance specifications used in the engineering development phases for

new products. Manufacturing Engineering (ME) consulted with me in

transitioning new products to the manufacturing floor to achieve low touch

labor rates (LEAN manufacturing) and high yield with low scrap rates. I

performed defect analysis of optical assemblies, determined the root cause

of defects, and revised work instructions to mitigate and eliminate further

quality and performance issues.

I worked closely with program managers, VP operations, manufacturing

engineers, and the principal systems engineer to execute the program


Overall success of my efforts resulted in the completion of $100 million of

delivered product while meeting all delivery schedules with no

delinquencies over the term of the contracts with substantially higher than

anticipated net returns due to increased efficiency.

Page 2

Resume of Dean H. Webster

1/2002 to 7/2007; Consulting Engineer to Bodkin Design & Engineering,

Trygon, Inc., and

R. D. Webb Co. for CAD support, system testing and data reduction;

technical writing, quality program support, and general design;

manufacturing, and process engineering support. Bodkin designs and builds

innovative optical systems with contracts from MDA and AFRL regarding

missile defense systems, Trygon designs innovative x-ray detectors

replacing film dosimeters, and Webb designs and builds laboratory vacuum


2/2001 to 12/2001; TyCom Ltd., Exeter, NH, High-Tech Component Engineer

Responsible for specifying and introducing new fiber optic and microwave

telecommunication components to the factory and supporting the product with

respect to performance and quality. I worked closely in the development of

tunable, DFB lasers. The critical requirement was the ability to tune and

control the very narrow spectral emission of the laser by controlling the

temperature of the device. The responsibility included working with the

system and technology designers to define the component specifications and

identify appropriate suppliers. In addition, this effort entailed defining

reliability and environmental requirements and the test methods to verify


3/2000 to 2/2001; Mentis Sciences, Inc. Manchester, NH Senior Program


Develop materials, methods, and systems to fabricate innovative radome

systems (PAC 3). Responsibilities include technical staff project leader,

tooling designer, contract management, and test systems development. I

presented program progress reports to the customer on a regular basis and

worked with the customer to meet program goals.

10/94 - 3/2000; Ion Optics, Inc. Waltham, MA. Product Development


Major responsibilities are manufacturing engineering and new product

development relating to IR instruments including pulsed broadband IR

emitters, NDIR and dispersive IR spectrometers, LWIR cameras, and circuits

to drive precision-pulsed emitters. Accomplishments include the development

of a patented pulsed IR emitter and associated electronics. I designed

and engineered the filament encapsulation and related manufacturing

processes. This included the design of semi-automated precision welding

equipment, automated IR radiance and precision resistance test stations,

and burn-in/life test stations. Wrote process operation instructions for

manufacturing and quality assurance. Have developed a broad understanding

in material surface modifications, spectroscopy, infrared detectors and

associated circuits, and imaging. Lead the development of the vendor's

processes and manufactureability of one-of-a-kind infrared waveguides used

in the Ion Optics

spectrometer. During this development, I wrote the SOW and quality

requirements related to this project. I engineered a proof of concept, in-

situ, pulsed laser, film thickness monitor. Performed optical lab bench


using filters, lasers, lenses, monochrometers, blackbodies, detectors, and

thermal imagers to verify the performance of these custom optics. Have

designed and prototyped many of the detector signal conditioner circuits

used. Software used is AutoCAD, Daqview, Labview, Matlab, and Excel.

2/92 to 10/94 R. D. Webb - Wellesley, MA Senior Product Engineer

Managed material characterization of advanced high temperature coatings and

substrates. Developed Carbon fiber/ Polyimide resin composite for a phase

II SBIR. Developed equipment and methods to perform thermal processing.

Performed contract material characterization using SEM and EDS.

Page 3

Resume of Dean H. Webster

10/88 to 1/92 Armtec Industries (Meggitt)- Manchester, NH Vendor Quality

Engineer Manager

Manage Vendor Quality. Improved manufacturability for castings and

machinings working with vendors and designers to minimize quality problems.

Develop turnkey PCBA suppliers. Manage ship to stock and source

inspection program. Perform pre-award surveys and quality audits. Verify

and report inspection findings with respect to threads, GD&T, and finish.

Solve vendor related technical problems. Manage vendor corrective action.

Managed RMA and customer return reporting. Apply SPC and participate in

TQM to improve vendor/buyer performance. Establish new procedures to comply

with ISO-9000 requirements. World-class manufacturing training (JIT).

11/83 to 8/88 AVCO Systems, Textron, Inc. Wilmington, MA Supplier

Quality Engineer

Apply quality program requirements of MIL-Q-9858 and Mil-I-45208 to

contract procurements. Write product assurance operation instructions.

Develop qualification plans. Secret Clearance granted.

EDUCATION: BS University of New Hampshire, Durham, NH

Additional training, educational courses, and seminars:

1985, Technical Writing and Editing; Northeastern University

1988, in house, 14 week course in SPC (Six Sigma); ARMTEC Inc.

1989, in house seminar in World Class Manufacturing (JIT); ARMTEC Inc.

1990, training in TQM; ARMTEC Inc.

2008, 16 week LEAN training; Insight Technology

On-going attendance of trade and SPIE seminars

References furnished upon request

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