Engineer Manufacturing

Dirk Kubernus

*** ******* ****

San Marcos, CA **069

760-***-**** abk33y@r.postjobfree.com

Summary

QUALITY & RELIABILITY ENGINEER with aerospace, telecommunication,

automotive and commercial industry background. Expertise in qualification

of new designs and introduction into manufacturing. Strategic visionary

with the unique ability to recognize and uncover problems, analyze all

elements and resolve failures. Ability to setup production and outgoing

quality requirements at contract manufacturing within the United States,

Mexico, China, Korea and Japan. Experience includes Electronic Surface

Mount Technology (SMT), High and Low Volume. Strengths in Writing and

performing test plans for Reliability Testing, QVT, ORT, HALT/HASS, Strife,

ESS and MTBF testing. Experience with environmental testing - Including

Temperature and Humidity Chambers, Thermal Shock, Vibration, IR Imaging,

Surge, Lightning and ESD testing. Successful record of developing processes

and procedures per ISO 9000 standards. Proficient at finding product

weaknesses and designing for manufacturability.

Professional Experience

Owens Corning, Napa, CA 2006 - 2009

Process/Reliability Engineer

Designed and improved equipment reliability for use in large stone veneer

manufacturing plant. Standardized key processes. Program Managed projects

- Supervised 2 to 12 contractors. Conducted Safety Reviews. Implemented

methods for continuous process improvement (CPI) in all areas of the

plant. Worked with maintenance on equipment repairs.

. Lead Six Sigma Green Belt Project resulting within a 3 month savings of

over $355,000 in equipment costs, improved operating efficiency (OE) by

9%, reduced equipment downtime from every 3 days to a 6 week scheduled

equipment preventive maintenance (PM).

. Introduced a different approach to measuring vibration energy which

resulted in reducing a scrap rate of over 30% into a sustainable rate of

8%.

. Award recognition of proactively taking on work to define a metric for

stone curing. Established parameters to reduce process variation and

improved efficiency.

. Selected by Leadership to work on Stable Operations Project with

Corporate Engineering (start of Lean Manufacturing efforts to engage

employees). Visual factory with real time scrap reporting. Allowed

operations to make faster judgments to bring processes with statistical

process control (SPC) limits.

. Brought insight to operations in areas of process capability & variation.

Helped maintain low scraps rates, improved quality and controlled

processes.

Independent Contractor, Windsor, CA 2005 - 2006

Quality and Reliability Engineering

Product evaluation - Design for Reliability & Manufacturability. Product

Qualification Testing.

. Provided HALT/HASS reliability training and hands on testing techniques

to Hewlett-Packard in Vancouver, WA. Saving on time to market and

reducing design errors.

. Performed new product introduction testing. Worked with Design Engineers

and Contract Manufacturers to ensure product robustness.

. Qualified Lead Free Solder processes to meet RoHS standards. Allowed the

company to sell products into Europe.

. Taught ESD Design rules to company engineering and became resource for

ESD knowledge.

Dirk Kubernus Page Two

PNI Corporation, Santa Rosa, CA 2001 - 2005

Quality Manager/Engineer

Qualify engineering designs; recommend changes for a more robust product.

Performed reliability testing on new products. Worked closely with Design

Engineering in Design for Manufacturability (DFM). Resolved manufacturing

issues at the supplier and contract manufacturing sites in China, Korea,

Japan and within the United States.

. Investigated and discovered a $100,000 loss in inventory of 1st time

failed units. Worked with the Contract Manufacturer to resolve all

manufacturing issues and repairs needed to salvage inventory.

. Updated difficult designs and created ways to make product easier to

manufacture.

Mahi Networks, Petaluma, CA 2001

Quality/Reliability Engineer

Start-up Networking Company. Setup Calibration, ESD and Reliability

programs.

. Organized a working calibration program meeting ANSI/NCSL Z-540 & ISO

9001 standards in less than 3 months. Positioned company closer to

obtaining ISO 9000 Certification.

. Standardized operating procedure for all customer requirements by

outlining a reliability program with supporting documentation. Authored

the process document which was published in a white paper for the

corporation's reliability platform.

Copper Mountain Networks, San Diego, CA 1999 - 2001

Quality/Reliability Engineer

DSL Networking Start-up company. Started an RMA Lab from ground floor up.

Implemented Calibration, ESD and Reliability programs.

. Started and lead Closed Action Teams to resolve design and manufacturing

issues.

. Developed and facilitated a Closed Loop Corrective Action Team to address

failures from design, manufacturing and field returns. Program was

successful and process / procedures became corporate standards.

. Resolved design issues with the DSL power supply protection circuitry,

which eliminated top RMA returns.

Hughes Network Systems, San Diego, CA 1993 - 1999

Quality Specialist

Qualified Engineering Designs. Performed environmental test on new

products. Recommend changes for a more robust design and DFM. Resolved

manufacturing issues at the supplier and contract manufacturing sites.

Setup ESD program. Qualified contact manufacturing sites. Analyzed

production fallout and RMA returns. Resolved failures to root cause.

Internal ISO auditing.

. Validated and challenged device operations beyond product thresholds

determined by Design Engineering using HALT (Highly Accelerated Life

Testing) methods. Identified major design flaw during qualification of

the Direct PC program which saved company from a 100% product recall.

. Identified, analyzed, and corrected current real life ESD design and

manufacturing issues. Resolved a major ESD problem during the beginnings

of the OnStar program. Using unique investigative methods, reduced

catastrophic failure rate of 42% down to 3%, improving quality, reducing

costs and meeting manufacturing deadlines.

. Created and documented a hands-on ESD training program. Conducted classes

for Engineers, Technicians and Manufacturing Support personnel and

instructed how ESD applies to their job function. The educational

instruction included actual ESD events, industry and manufacturing

problems with practical, cost effect ways of resolving them.

. Elected Vice-President of the Southern CA Chapter of the ESD Association.

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Hughes / JVC Technology, Carlsbad, CA 1992 - 1993

Sr. Electronic Technician

Tested and oversaw all troubleshooting of new designs to component level.

Built new test fixtures. Developed test processes for production testing.

. Resolved inventory issues through warehouse organization and implementing

new component tracking system.

Hughes Missile Systems (Formally General Dynamics - Convair Division),

San Diego, CA 1983 - 1992

Final Checkout Group Leader

Group leader at final checkout on cruise missile program. Lead technicians

and mechanics on second (2nd) shift. Worked in a Field Engineering capacity

calibrating TLAM Guidance Systems. Test and troubleshot Cruise Missiles

down to component level.

. Saved company over $500,000 in one year through over fifty (50) approved

employee suggestions. Recognized by numerous awards.

. Advocate of process improvements and selected to join review board.

EDUCATION

Currently completing Bachelors Degree in Technical Management at

DeVry University, San Diego, CA

Maintaining a G.P.A. of 4.0

Dean's List

Associate Degree - Electronics

DeVry Institute of Technology, Chicago, IL

Presidential Honor Roll - G.P.A. 3.74

Lean Manufacturing and Six Sigma Green Belt Trained.

Statistical Analysis and Minitab Trained

Professional CERTIFICATIONS

iNARTE Certified ESD Engineer

ISO 9000 Certified Auditor

Vice-President of the Southern CA ESD Chapter from 1998 - 1999

President, Student Chapter of the Instrument Society of America 1982 -

1983

Professional ASSOCIATIONS

International Association of Radio, Telecommunications and

Electromagnetics

ESD Association

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