Injection Molding Design

ERIC A. HIGGINS, PMP

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

Phone: 412-***-****

Cheswick, PA 15024 E-mail: **************@*****.***

September 15, 2010

To Whom It May Concern;

My experience extends through a breadth of product development

knowledge areas including product design, assembly, materials consultation,

manufacturing, and project management activities including Design Control

documentation and risk management. This experience includes design

development, design analysis (FEA, tolerance, statistical), identification

of key product characteristics, conducting sensitivity analysis of product

performance interactions, prototyping, product testing, managing multiple

mold tooling projects as well as hands on experience with injection molding

process optimization.

I have worked with a broad range of materials, machines and auxiliary

equipment. I have experience determining and coordinating production and

supply chain requirements. I have generated costs and quotations for part

pricing, including inserts, secondary operations, packaging and shipping.

The following experience may be of specific interest;

. Lead Engineer for engineering team to design & develop a patient

interface Full Face mask for application of noninvasive ventilation.

Responsibilities include Mechanical Design, Process Design,

documentation compliant to Design Control, support of Verification and

Validation and design transfer.

. Authored Process Development Procedures, Work Instructions and Forms

for Philips Respironics' Quality System. This procedure introduces a

detailed strategy of process design measures, which incorporate

engineering activities with business goals. It provides communication

tools conveying plans, criteria, status, cost tracking and issue

tracking. It also integrates process design into the product

commercialization and validation processes.

This procedure offers improved reliability of product data, product

quality, repeatability, efficiency, reduced cost and time associated

with commercialization, as well as satisfies FDA requirements. It

utilizes work instructions and standardized forms that incorporate a

quantitative and methodical engineering approach to process

characterization. These include; capability study, melt rheological

study (relative viscosity), cavity balance, gate freeze, cool time

optimization, capability studies and DOE's. The applications of

statistical methods are used in establishing process design

specifications.

. Led a team of 5 engineers for implementation, validation and

integration of Process Development Procedures into Product Development

activities. This procedure and associated documentation were

validated on multiple projects.

. During development and production of new programs at Sensus

Technologies, I was responsible for tooling and manufacturing of

molded products. I was a project team member in an international

development of ICE (Intelligent Communications Encoder) products, the

most technologically advanced AMR (Automated Meter Reading) system in

the utility industry.

. One of my key roles as a Sr. Plastics Engineer was managing product

commercialization activities, assisting and ensuring productivity,

efficiency and pursuing cost reduction / production improvements.

. Process control has been an essential element in achieving key

objectives such as product quality improvements, cycle and scrap

reduction. I have trained process technicians on process control,

received RJG Master Molder certification, and received certified

training for Design of Experiments (DOE).

Thank you in advance for your time. I look forward to further discussing

the position.

Sincerely,

Eric A. Higgins, PMP

Attachments: (3)

ERIC A. HIGGINS, PMP

109 Black Oak Drive

Phone: 412-***-****

Cheswick, PA 15024 E-mail: **************@*****.***

OBJECTIVE: Capitalize on a unique balance of experience in product design,

development and manufacturing by serving a key role in product

commercialization. Fulfill a position that can contribute to Product

Development activities, providing efficient utilization of resources,

quality product and expedited schedules.

EDUCATION / B.S. Plastics Engineering, May 1996, The Pennsylvania

State University

CERTIFICATION: A.S. Mechanical Engineering, May 1994, The

Pennsylvania State University

RJG Master Molder SM

Certification - Penn State University, June 2008

Project Management Professional (PMP) - Certified,

June 2009

TRAINING OF INTEREST:

. DOE - Penn State University; 2007

. Minitab statistical software; Intro to Minitab, Basic Statistics,

Statistical Quality Control, Factorial Designs; 2007

. GD&T - Penn State University; 2007 & 2008

. Moldflow analysis software - MPI-e Standard 1, Advanced Flow training,

Advanced Cool and Warp, 2008

. Process Validation (FDA Medical Requirements) - Barile and Associates

Consulting, 2007

. Process Development & Validation - Becton Dickinson, 2007

. Design Control Industry Training - Barile and Associates Consulting, 2008

. Process Validation for Medical Injection Molding - Penn State University

2008

. ANSYS Software training - 2008

. Project Management Education for PMP Certification requirements - 2008

SOFTWARE Moldflow (Autodesk), C-Mold, ANSYS, Pro/E, Pro-Mechanica,

Unigraphics, AutoCAD, Cadkey

EXPERIENCE: SAP, BPCS, Intrac, Lotus, Microsoft Office Suite with Power

Point, Project, Visio, Sharepoint

Minitab (statistical & DOE software), Maximize DOE

Optimization, Respironics Issue Tracking

ACCOMPLISHMENTS / CONTRIBUTIONS;

. Engineering Lead in developing and releasing a patient interface full

face mask to market 2009.

. Engineering Lead & PM for development of a new mask Entrainment Valve

with Quick Release.

. Authored Process Development Procedures and associated documentation

for Respironics' Quality System.

. Team leader for implementation, validation and integration of Process

Development Procedures into Product Development Procedures. Also, led

efforts to develop training materials and presentations on

instructions.

. Team member for implementing Process Validation activities (IQ, OQ, PQ)

into commercialization process.

. Coordinated training for Moldflow and Minitab software in support of

product and process development.

CORE COMPETANCIES;

Plastic Product Design and Development, Mold Design, Process Design &

Development, Materials, statistical applications, and document control.

UNIQUE EXPERIENCE;

. Silicon Injection Molding, Overmolding (w/ Si, TPE, TPU, PC/ABS),

various insert molding applications (acrylic lens, decorative films,

threaded inserts, cold formed inserts, surgical blades and springs),

ultrasonic welding, heat staking, and coating applications (dip and

spin coatings).

. Travel to Asia Pacific to provide training and project oversight in

development transfer to production.

. International work experience; China, Hong Kong, Philippines,

Singapore, Malaysia, Germany.

. Interface with physicians, therapists, nurses, DME customers and

patients to evaluate product needs, performance and

preference.

. Penn State University, Behrend College Alumni Board of Directors -

current member.

ERIC A. HIGGINS, PMP

109 Black Oak Drive

Phone: 412-***-****

Cheswick, PA 15024 E-mail: **************@*****.***

EMPLOYMENT HISTORY:

Philips Home Heath Care Solutions 05/2006 - current

Mechanical Engineer Phone: 800-***-****

Company Focus: Disposable medical devices for global sleep and respiratory

markets

Experience;

. Product Development / documentation: Lead cross-functional teams

through product development procedures, from research concepts through

commercialization and design transfer into production. Work with

Regulatory, Quality, Product Assurance, Marketing, Project Management

and Operations Departments on Risk Assessment, DFMEA, Product

Requirements Document, Efficacy, Bio-compatibility Assessment, among

other deliverables in Design History File. Conduct design review

meetings, record minutes and track issues, compliant to design control

Quality System Procedures / Quality System Records (QSP/QSR). Develop

and qualify product design specifications. Approve Engineering

Qualification test reports. Maintain Bill Of Materials (BOM),

Engineering Qualification Test Plans (EQT), coordinate mold

procurement, sampling, inspection approvals and production

requirements.

. Product Design: Lead activities to finalize design, component model,

drawing updates and specifications. Evaluate design objectives,

manufacturability and assembly (DFM/DFA). Obtain and test prototypes.

Modify design to achieve performance objectives. Utilize hand-

calculations, prototypes, and ANSYS to estimate product performance.

Generate correlations of product features to performance results and

develop sensitivity ratios to evaluate key features. Evaluate

performance characteristics at predicted worse-case boundary

conditions. Incorporate tooling and process variation in dimensional

tolerance reviews. Evaluate Gauge R&R data and statistical performance

capability. Conduct GD&T and tolerance stack-up reviews of drawings.

. Product Analysis: Create solid model, determine constraints and conduct

analysis; mold-filling & ANSYS.

. Process Development and Validation: Develop Protocols, coordinate and

assist with engineering studies such as cavity balance, relative

viscosity, and gate freeze studies. Establish conditions to achieve

product requirements, reduced scrap rates and cycle times. Conduct DOE

with ANOVA. Review and approve documentation.

. Troubleshooting: Troubleshoot injection molding processes and product

failures.

. Problem Solving: Evaluate (DFMEA/PFMEA), define design criteria,

conduct Design Of Experiments (DOE), Pareto, correlation and regression

analysis, MSA

. Training: Provide engineers and technicians with training of process

development and control & design control.

. Engineering Systems Improvements: Authored, implemented, and provided

training on new engineering development procedures, work instructions,

and forms.

Omni Plastics 09/2003 - 4/2006

Sales Manager (project development) Phone: (814) 838-

6664

Company Focus: Custom injection molding of medical, pharmaceutical and

diagnostic products.

Experience;

. Project Management: Manage customer related activities including

quotations of molded parts, tooling and production for custom injection

molder. Estimate cycle times, production lead-times, calculate product

costs and production requirements & capacity. Prepare Request For

Quotations for outside suppliers, specify materials, purchase

materials, conduct material rheological inspections, and Prepare

Customer Quotations.

. Cost Estimations: Provide cost estimations of product manufacturing for

project development budgets.

. Other: Coordinate and assist with engineering studies such as cavity

balance, relative viscosity, and gate freeze.

Albis Plastics 05/2001 - 5/2003 (Due to

department elimination)

Tech Service Application & Development Engineer Phone: (888)

252-4762

Company Focus: Global supplier of engineering resins, custom and licensed

compounder for Bayer, BASF, Eastman.

Experience;

. Design Consulting: Assist material customers with part design, material

selection, mold design, and processing.

. Troubleshooting: Troubleshoot injection molding processes and product

failures.

. Problem Solving: Evaluate (DFMEA/PFMEA), define design criteria, and

conduct Design Of Experiments (DOE).

. Training: Provide technicians with training of process development and

control.

ERIC A. HIGGINS, PMP

109 Black Oak Drive

Phone: 412-***-****

Cheswick, PA 15024 E-mail: **************@*****.***

Sensus Metering Systems 03/1998 - 05/2001

Senior Plastics Engineer Phone: 724-***-****

Company Focus: Design and manufacture automated metering and controls

systems for the Utility industry.

Experience;

. Product Analysis: Create solid model, determine constraints and conduct

analysis; mold-filling, cooling, shrinkage, warpage and

stress/structural analysis. Research and coordinate testing of new

materials.

. Process Development: Coordinate and assist with engineering studies

such as cavity balance, relative viscosity, and gate freeze studies.

Establish conditions to achieve product requirements, reduced scrap

rates and cycle times. Conduct DOE with ANOVA analysis. Review and

approve documentation.

. Project Management: Manage activities including quotations of molded

parts, tooling and production for custom injection molder. Estimate

cycle time, estimate resource requirements, and calculate product costs

and production requirements. Prepare Request For Quotations, specify

materials, supplier selection and contract terms.

. Troubleshooting: Troubleshoot injection molding processes and product

failures.

. Problem Solving: Evaluate (DFMEA), define design criteria, conduct

Design Of Experiments (DOE), utilize analysis tools such as IR

spectrometry, FEA, Fault tree analysis.

. Training: Provide technicians with training of process development and

control.

. Equipment Selection: Identify requirements and suppliers of machines,

robots, and secondary equipment such as ultrasonic welding and heat

staking. Make recommendations for purchase

. Cost Estimations: Provide cost estimations of product manufacturing for

project development budgets.

Rehrig Pacific Co. 05/1996 - 03/1998

Design Engineer Phone: 814-***-****

Company Focus: Design and manufacturing of plastic structural containers

for various industries.

Experience;

. Product Design: Component modeling with Pro-E and Unigraphics. Obtain

and test prototypes. Modify design to achieve performance objectives.

. Product Analysis: Create solid model, determine constraints and conduct

analysis; mold-filling, cooling, shrinkage, warpage and

stress/structural analysis. Research and coordinate testing of new

materials.

INTERNSHIPS:

Truck-Lite 05/1995 - 10/1995

Engineering Assistant Falconer, NY

Company Focus: Design and manufacture lighting systems for tractor

trailers, heavy equipment, and farm equipment.

Experience;

. Product Analysis: Create solid models and conduct mold-filling and

cooling analysis.

Triangle Tool (subsidiary of Plastek) 05/1994 - 05/1995

Drafting Intern Erie, PA

Company Focus: Design and build molds for injection molding.

Experience;

. Mold Design: component modeling, drawing updates and specifications,

cutter-path generation.

SMC (Saegertown Mfg. Co.) 05/1993 - 08/1993

CNC Lathe Operator Erie, PA

Company Focus: Design and produce cold forming, cold forging and cold

headed, precision machined components.

Experience;

. Machining: Operate CNC lathe.

Letters of recommendation and references are available upon request.

Contact this candidate