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Engineer Project

Location:
Weaverville, NC, 28787
Posted:
May 03, 2010

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Resume:

SUMMARY OF QUALIFICATIONS

Experienced technical manager with more than 15 years leading project

teams and work crews in fast paced multi-disciplinary environments

including R&D, plant and operations engineering, residential construction

and daily production supervision. Active hands-on leadership in personnel

and team development - sponsor/facilitator of highly sucessful standing and

ad-hoc teams involved in equipment selection, new product development, and

process engineering. Well regarded with a proven record of effective

personnel development and team building. Flexible and competent at multi-

level communications engaging all levels of the organization from C-level

to the shop floor.

SKILLS SUMMARY

Project Management Design & Engineering Root-Cause Analysis

Project Documentation Management & Supervision Equipment Design

Automation - Robotics Team Building

Design For Manufacture Capital Justification Budget Development

Marketing & Sales

PROFESSIONAL EXPERIENCE

management and supervision

FIBER OPTIC AND COAXIAL CABLING, ENGINEERING MANAGEMENT, CAPEX AND

BUDGET GENERATION

SUPERVISOR, ENGINEERING MANAGER AND CHIEF ENGINEER. RESPONSIBLE FOR

PERSONNEL HIRING, FIRING, EVALUATION, BUDGETING, INTERFACE WITH

OPERATIONS, QUALITY, RESEARCH AND MARKETING ORGANIZATIONS. PROVIDED KEY

TECHNICAL CONTACT AND TEAM DIRECTION FOR PRODUCT AND PROCESS TRANSFERS.

INCLUDED MANAGEMENT FOR AS MANY AS 64 (18 DIRECT) PERSONNEL FROM

PRODUCTION LEVEL TO TECHNICAL STAFF.

Scope of Work:

. Site Manager for startup of cable manufacturing facility near Jakarta,

Indonesia - duties included hiring/firing, import coordination,

manpower scheduling and synchronization with equipment supplier (Nokia)

of cable manufacturing equipment. Rotating position (6 weeks on/off)

required startup and transfer of local office including personnel,

establishment of facility, equipment ordering and confirmation in

addition to interface with quasi-governmental joint venture partner and

import/export office.

. Leader of cross-functional plantwide team responsible for major product

transfers from Europe to US facility- achieved a 60+% reduction in the

normal transfer time with 98% first pass yield. Product for overseas

customers in Egypt and India. Required knowledge of export,

manufacturing and Commerce Department constraints as well as detailed

product characteristics, testing, and new FRPE material testing and

approval. Project resulted in customer success award from Egyptian

cable concern.

. Managed Engineering Support Team of eight engineers and 3 technicians

responsible for over 24 extrusion lines and ancillary processes

including bulk storage and transfer systems. Reduced turnover by

1/3rd.

. Sponsored first pilot production employee team at a fiber optic cable

manufacturer to evaluate and select their production systems. Team

ownership of equipment proved to enhance switchover. Coached team in

writing documentation and developing training plan and implementation.

Immediate quality enhancement taking first pass yield from 95% to 98%.

Resistance to change nullified.

. Created capex proposal and negotiated approval for $36 million capital

expansion (2000-2001). Managed team responsible for implementation of

plan at Claremont, North Carolina facility. Also directed team to

implement plant expansion project in High River, Alberta.

. Responsible for capital proposals for cabling facility, including

economic justification and supporting document generation beginning in

1992 ($2.5 million), 1993 ($6.4 million) 1994 ($9.2 million) and 1995

($11.5 million), 1998 ($8.8 Million - Jakarta, Indonesia), 1999 ($5.5

million) and 2000 ($36 million)

. Applied work standards to three primary production processes (wire

draw, braiding and cable jacketing) to achieve 13%, 23% and 34%

improvements, respectively, in throughput in one year. (1995)

. Implemented Visual factory concepts for production in a coaxial cable

manufacturing facility, reducing changeover downtime by over 33%.

PROFESSIONAL EXPERIENCE (continued)

MANAGEMENT AND SUPERVISION

. SUPERVISED SAP ERP MODULE IMPLEMENTATION (MM & PP) INCLUDING THE

COMPLETE LEGACY DATA CONVERSION

. Production initiatives supported increased performance of plant to >96%

first pass yield and 98% equipment uptime over six months. (original

benchmarks 91% first pass yield, 89% uptime)

Engineering and Technology

FIBER OPTIC AND COAXIAL CABLING SYSTEMS, EXTRUSION, INDUCTION WELDING,

ALUMINUM DRAWING

PROJECT AND PROCESS ENGINEERING SUPPORTING COAXIAL AND FIBER OPTIC CABLE

MANUFACTURING. FAMILIARITY WITH POLYMER EXTRUSION AND MATERIAL HANDLING

SYSTEMS INCLUDING LOSS IN WEIGHT FEEDERS, VACUUM TRANSPORT, EXTRUSION

PROFILING, AND CABLE PROCESSING. PRIMARY EXTRUSION RESOURCE - HANDS-ON

PROCESS AND MANUFACTURING TROUBLESHOOTING WITH PP, PE, PVC, XLPE, PBT,

FRPE COMPOUNDS AND ADDITIVES. RESPONSIBILITIES INCLUDED MAINTENANCE OF

OPERATOR SETUPS AND TOOLING REQUIREMENTS, COMPOUND DISTRIBUTION SYSTEMS

AND EXTRUDER PROFILES.

Scope of Work:

. Development of a unique cable stranding process for a Japanese

customer - returned $10 million annually

. Implemented quick change techniques for a 78% reduction in setup times

- resulted in >$2 million in annual savings, eliminating the need to

purchase additional extrusion capacity.

. Developed revised extruder feed system and operating profiles for 22%

increase in output.

. Lead engineer for new coaxial product line (QR ) utilizing continuous

welding of roll-formed aluminum outer shield. Supported viability of

product that was close to cancellation; moved product to >60% of

product sold.

. Invented cable cleaning and lubrication process to aid in drawing

operation - reduced failures by 12%

. Roll drawing process enhanced through use of ceramic bearings over

metal at induction welder - bearing failure dropped over 68%.

. Introduced new centrifugal coolant recycling system reducing material

cost by 11%.

. Developed tooling setup database utilizing pictorial and hypertext

help. Maintained operator setups with specified tooling, draw down

ratios and extruder settings.

. Implemented plant-wide Root Cause Analysis program - training,

execution and follow-up resulting in 12% reduction in recurring

failures in first 4 months.

. Primary extrusion resource - hands-on process and manufacturing

troubleshooting with PP, PE, PVC, XLPE, PBT, FRPE compounds and

additives including blowing agents: celogen, Wil-Foam and nitrogen

injection.

. Developed and taught extrusion classes for plant associates and

engineers. Instruction in polymer and extrusion behavior, tooling

handling and line optimization and troubleshooting.

. Implemented new tooling database and use of visual factory techniques

to reduce setup errors by over 18% and downtime by over 33%.

. Vendor development and selection for equipment and materials.

Coordinated with materials research to outsource a key PP material

subcomponent with a 22% cost reduction. Switchover completed in record

time three months vs. eight. Required vendor development and quality

compliance process implementation

. Development and direction of plant cost reduction portfolio (>$24

million saved over 4 years) representing an 18% reduction in product

cost (direct and indirect labor, materials and utilities)

. Patent Granted - US patent number 7346244 & Europe 1243957 ("Coated

central strength member for fiber optic cable with reduced shrinkage,"

Russell W. Gowan, Brian Risch, Wayne Cheatle, Publication Date: January

17, 2008; Priority Date: March 13, 2001 Granted: March 18, 2008.)

PROFESSIONAL EXPERIENCE (continued)

engineering and Technology

NUCLEAR SYSTEMS AUTOMATION, MACHINE DESIGN, DOD & DOE PROJECTS, HVAC

DESIGN AND PROJECT ENGINEERING SUPPORTING EQUIPMENT DESIGN AND AUTOMATED

MANUFACTURING/MEASURING OF NUCLEAR POWER COMPONENTS INCLUDING GLOVE BOX

SYSTEMS, ROBOTICS, WEIGHING SYSTEMS, CLEANING AND COATING SYSTEMS.

FAMILIAR WITH SPECIAL METAL MATERIALS INCLUDING HASTELLOY, NIOBIUM,

INCONEL, MONEL AND VARIOUS STAINLESS STEELS. WORKING KNOWLEDGE AND

APPLICATIONS OF POLYMER SEALING MATERIALS INCLUDING NITRIL, VITON, EPDM,

BUNA, TEFLON, NYLON, PP AND PE. APPLICATION OF PNEUMATICS, HYDRAULICS,

DIGITAL AND ANALOG DRIVES, GEARING SYSTEMS AND ROBOTICS.

Scope of Work:

. Developed second generation nuclear fuel splitter process using

pancake drive and pneumatic systems.

. Capital justification, purchase and installation of carbon bed

scrubber system reducing emissions by over 80%

. Designed cleaning and coating system to eliminate use of solvent

cleaning process. Replaced trichlorotrifluoroethane (Freon TMC)

material with liquid CO2 cleaner and processing equipment.

. Developed quick-change fixture for Electron Beam welding system -

reduced downtime by 42%

. Plant wide resource and designer for multiple specialized fixture

designs for high precision measurements of complex geometry of

nuclear propulsion systems 0.00001 in.) using laser and LVDT

devices.

. Developed testing and manufacturing systems and protocol for CEBAF

accelerator systems.

. Designed and implemented a control rod spring tension measurement

system utilizing load cell, ballscrew and digital hysteresis linear

measurement devices.

. Designed and programmed hydraulic flow measurement device for cooling

loop systems for control rod drives.

. Robotic system end effector design - material handling of hazardous

materials for Babcock and Wilcox, Pantex and Morton Thiokol

. Multiple glove box containment systems - designs included interlocks

with argon leak detection

small Business Development and management

NATURAL FOODS MANUFACTURER, ARCHITECTURAL FIRM, SMALL BUSINESS OWNER

RESPONSIBLE FOR STARTUP, CAPITALIZATION, BUDGETING, PRODUCT DEVELOPMENT,

SALES, MARKETING, BOOKKEEPING, COMPLIANCE WITH REGULATORY REQUIREMENTS,

WEBSITE AND GRAPHICS DESIGN, ENGINEERING, PROJECT MANAGEMENT AND

CUSTOMER INTERACTIONS.

Scope of Work:

. Startup: Founder and CEO for natural chocolate manufacturer.

o Responsible for business plan development, FDA and USDA compliance.

o Marketing and branding development including product label graphics,

packaging design and selection and website design.

o Developed first viable recipe. Documented GMP standard for production

and testing.

o Created labels and packaging to assure product identity and freshness.

. Small Business: Owner for architectural firms supplying commercial and

residential stone products.

o Responsibilities included sales and marketing, engineering,

architectural element design and project management for Tudor and

Gothic residential projects nationwide.

o Working knowledge of construction concepts including familiarity with

NFPA and National Building Codes.

o Design for manufacture principles applied to custom limestone and cast

stone products.

o Sole responsibility for North Carolina division which was the primary

profit maker - over 48% of gross profits in a small company of five

people. Only division with a net profit for three years running.

Increased division sales 5X from $60,000 (2005) to over $375,000

(2008).

EMPLOYMENT HISTORY

Craftsman custom design - Weaverville, North Carolina

Owner, 2008 to present

tudor artisans, inc. - Hendersonville, North Carolina

Senior Partner/Owner, 2005 to 2009

ulimana, inc. - Asheville, North Carolina

Owner, CEO, 2005 to 2007, Ongoing Consulting

Alcatel Telecommunications. - Claremont, North Carolina

Sr. Engineer, Engineering Team Leader, Chief Engineer, 6 years

Belden Wire and Cable. - Tompkinsville, Kentucky

Senior Manufacturing Engineer to Supervisor, 1 year

Commscope inc. - Catawba, North Carolina

Senior Project/Process Engineer, 5 years

Babcock and Wilcox, NNFD - Lynchburg, Virginia

Engineer I to Senior Project Engineer (IV), 7 years

EDUCATION

University of north carolina - asheville, north carolina

BUSINESS MANAGEMENT (CERTIFICATE OF MAJOR)

GPA: 3.82/4.0, 3.89/4.0 in major

HONORS: CHANCELLOR'S AND DEAN'S LIST, SIGMA BETA DELTA & BETA GAMMA

SIGMA HONOR SOCIETIES

SOUTHERN POLYTECHNIC AND STATE UNIVERSITY - MARIETTA, GEORGIA

BACHELOR SCIENCE MECHANICAL ENGINEERING TECHNOLOGY

GPA: 3.1/4.0

ADDITIONAL COURSEWORK

Root Cause Analysis - Apollo Training

Emotional Intelligence Training - MindSpring Institute

Non-Violent Communications Training - Certificate

International Association of Coaches - Registered Career Coach

American Society of Trainers and Developers - Member

Daniel Management Center - University of South Carolina

Management Development Program for Engineering and Technical Leaders

Leadership through People Skills

Collaborative Negotiation

Finance for Non-financial Managers

PERSONAL

Provide ongoing seminars in business and marketing concepts to future and

new small business owners in the Asheville, NC area.

Tutoring and mentoring of three special needs kids with autism spectrum &

Asperger's syndromes.

Presentation and trainings on Neuro-Linguistic Programming to help

individuals build rapport.

Recently delivered training at the North Carolina Center for the

Advancement of Teaching, Cullowhee, NC

Proficient with AutoCAD, Sketch Up, MS Project, Microsoft Office and

graphics design, including Adobe Photoshop & Illustrator and QuickBooks

programs.

Eagle Scout, Troup 268, Atlanta, Georgia: Assistant Scoutmaster 1977-1979;

Order of the Arrow

Previously maintained a DOE "Q" clearance



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