Engineer Six Sigma

Dan Earnhardt

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

Williamsburg, VA 23188

Phone: 757-***-**** Email:

************@*******.***

PRINCIPAL ENGINEER, SIX SIGMA BLACK BELT

SUMMARY

Having extensive experience as a certified Six Sigma Black Belt, I excel in

statistically-based analysis and DOE-based investigation. I have received

several design Patents, one process Patent, technical achievement awards

and financial contribution awards. My expertise includes grammatically-

correct technical writing, team leadership and training.

EXPERIENCE

CooperVision, Norfolk, Virginia

Principal Engineer, Six Sigma Black Belt 2002-Present

As one of the two certified Six Sigma Black Belts in our division, I lead

all technical analysis for the plant. My expertise has lead to frequent

involvement in worldwide technical improvement teams, with extensive

overseas travel involved, to England and to Puerto Rico.

Typical Accomplishments:

. Identified inaccurate plastic mold-fit issues as a primary

contribution to production yield losses in our Puerto Rico plant,

while serving as the International Fit Measurement Team Leader.

. Assisted our plant in England with start-up yield improvements in our

Silicon Hydrogel product line, being awarded a significant financial

contribution award for accomplishments over an 8-month period.

. Trained engineering group in the use of Minitab for analyzing data

sets. This included Designed Experiment (DOE) applications and ANOVA

(analysis of variance) use, to obtain an assessment of validity (by

way of "P-Values"), in the assumption of significant differences and

in the use of "Test for Equal Variances," for determining whether

measured differences in standard deviations are statistically

significant.

. Designed and developed Air Gages for measuring part-to-part clearances

of between 4 and 80 microns. These gages measure inside or outside

diameters and have a repeatability of +/- 1.5 microns, providing the

corporation's first opportunity to measure their primary processing

components' critical fits.

. Improved rolled throughput yields in our 73% Surfilcon Lens, moving

yields from 14% to 40% in 3 months.

. Reduced occurrence rate for holes in our highest-volume product line,

from 13%, down to 1%, by identifying Mold-Fit Target and Monomer

Filling Station Settings as the primary contributors and deriving and

instituting their optimum values.

Siemens Automotive, Newport News, Virginia

Staff Engineer 1982-2001

As the lead automated test project engineer, I managed the design phase,

quoting phase, build phase, institution, calibration and optimization of

the divisions' first automated adjust-and-test lines for fuel injectors.

As a Flex-Fuel Injector design engineer, I was instrumental in improving

the division's first Flex-Fuel product for Chrysler Corporation.

Typical Accomplishments:

. Designed and developed a high-speed (500 micro-second), pressure re-

supply test cavity for fuel injector flow testing.

. Designed and developed a precision 0.1sccm) pneumatic leak test

system.

. Designed and developed an automatic system for maintaining pressure

transducer calibration.

. Served as Project Engineer on the first automated adjust-and-test Fuel

Injector lines, each costing on the order of 2.5 million dollars.

Received a corporate technical achievement award for this work.

. Led the design improvement of the division's first Flex-Fuel Injector,

developing a titanium nitride-coated needle and receiving two Patents,

for needle alignment and reduced-impact landing features.

. Invented and received a Patent for a substitution air-based test

process, using compressed air rather than using brake fluid, for our

anti-lock brake valve test line.

. Served as project leader to obtain and institute the automated test

system for processing the air-tested anti-lock brake valves.

. Received a significant financial contribution award for the

development and sale to the customer, of the substitute air-test

system.

TECHNICAL KNOWLEDGE

Six-Sigma Process (DMAIC), DOE, ANOVA, 8D, Geometric Dimension &

Tolerancing, Team Leadership & Training, Technical Project Management, MS

Office, Excel, Project & Word, Access Database Queries, Automated Test,

Automated Assembly, Air-Gage Design, Gage & System Calibration, Technical

Writing, Minitab Applications, FMEA, DFMEA, SIPOC, 5-S, Lean Six Sigma,

SPC, PSER, Gage R&R

EDUCATION

Bachelor of Science in Applied Physics from East Carolina University, Six

Sigma Black Belt, Technical Project Management, Geometric Dimensioning &

Tolerancing, Value Analysis, DOE Application, Lean Manufacturing, Dynamic

Measurement Systems

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