Engineer Project Manager

Project Manager & Sr R&D Engineer Medical Devices & Converting Equipment

I am Genival Barros, specialist in the introduction of new products,

processes, equipment, and project management. In my capacity, I work

providing coordinating technical support for manufacturing process. Work

with R&D in the research, design, and development of new processes and

products, applying principles and techniques of project management,

mechanical engineering, and mathematical analysis.

Coach and coordinate the work of technicians and junior process engineers.

Help, and many times, take the lead of troubleshooting problems in the

product lines.

Work closely with regulatory affairs, in order to make sure that all

processes, procedures, and validations do comply with the rules set by the

regulatory agencies. Provide project management, troubleshooting, and know

how support to overseas plants.

Summary

> Team leader who thrives working with cross-functional teams, designing

and developing effective, efficient, scalable, and high quality

processes and equipment through the application of engineering and

Lean/Six Sigma principles.

> Customer focused hands-on project manager, driving projects towards

results. Creative thinker with sharp analytical skills. Problem solver

and Creator of solutions that are simple, cost effective, and focused on

the future of the manufacturing process (Certified 6-sigma Black Belt).

> Lead design, development, fabrication, commissioning, and full

implementation into manufacturing of new technology, tooling, fixtures,

equipment and automated systems for pilot and/or manufacturing processes.

Support the continuous improvement of legacy production lines.

> Outstanding training and coaching skills, helping engineers and

technicians achieving their fullest potential in a short time.

> Expertize in: manufacturing, cost reduction, statistical comparison &

analysis, manufacturing performance indicators, OEE increase,

productivity generation, process development, operations, strategy,

logistics, lean manufacturing, capital projects & business case.

> Over 15 year experience as an engineer in: Plastic & Paper film handling

& Converting, Coating, Drying and converting of Films & papers,

Equipment design, robotic factory automation, aseptic environment, device

manufacturing, micro-fluidics, OEE, SPC, Process Improvement, KAIZEN, Six

Sigma.

Career Achievements

> Led project teams in a series of Lean manufacturing projects. Implemented

SPC in key parts of the manufacturing process. Increased output of

manufacturing in 30% at the same time that increased capacity of process

bottlenecks in 50%.

> Introduced slot coating technology producing precise deposition of

chemistry layers on diabetes sensors. Conducted series DOE's that led to

the elimination of defects such us sensor run ups, delamination, and

signal variability.

> Successfully created and deployed high volume equipment that measures

Electrochemical Impedance Spectroscopy (EIS), which helps predicting the

performance of a sensor and eliminated destructive tests, saving more

than $3M in investments.

> Created a novel method of metal electroplating, which improves the

quality of the metallization, at the same time that reduces the process

cycle time in 5x.

> Through a series of engineering studies, found the root cause of an

occurrence that caused the signal of a considerable number of sensors to

fall out of the specification. The elimination of the problem, prevented

the loss of more than 10% of the sensors produced during many months,

which saved $Millions in revenues.

> Decreased the change over time of a slot coating line from 3 hours to 50

minutes, through the application of lean manufacturing and Kaizen

techniques.

> Solve a problem of dimensional stability on laminated flexible circuits

of copper and polyimide, though DOE and least-squares calculations that

resulted in savings of more than US$ 250 K / year.

> Created a process of stabilizing surface tension of substrates to solve

the problem of bond variability on flexible films through the application

of Six Sigma and Shainin techniques, which resulted in savings of nearly

US$ 400 K / year.

> Eliminated the incidence of de-wet problems by controlling viscosity of

the adhesive and surface tension of the substrate, which resulted in

savings of nearly US$ 50 K / year.

> Lead a Kaizen event and implemented the actions derived from it,

preparing a new site for high volume production of digital media paper

that resulted in: 1) Reduction of the shop floor area to 40% of the

original; 2) reduction of the headcount to 70% of the original; 3) The

event will generate savings of more than US$ 2 millions / year.

> Improvement of the production process of a facility for the production of

digital media paper. Removal of bottlenecks and constraints; reduction of

the waiting time in the line; automation of all labeling process; and

troubleshooting of the slitting equipment. Results: 1) increase of 15% in

the throughput; 2) Reduction of 40% of the overtime.

> Decrease the contamination of the product to six sigma levels by

designing a new filtering system for adhesive and cleaning fluids that

contacted the substrate. In addition to that, the pressure drop of the

delivery system was reduced, which eliminated the pump cavitation when

operating with adhesives of high viscosity. This project resulted in

savings of nearly US$ 70 K / year.

> Redesigned the whole process of filtration, flow control, and coating of

water base adhesive at the manufacturing of flexible circuits, which

resulted in the increase of capacity of nearly 300%.

> Development of a new palletizing system, eight times cheaper than out of

the shelf models in the market.

> Managed a project of installation of a new workcenter to produce digital

media paper. The project took 6 months from inception to end. Results: 1)

More than US$ 1 million / year savings; 2) The new workcenter is the

leanest workcenter of the entire paper flow. It has been used as a case

study for lean manufacturing.

> Implemented a project to increase flexibility in the workcenter with the

second highest volume of color paper production. Results: 1) Doubled the

number of product to run at the workcenter; 2) Increase the workcenter

efficiency in 3%, even with the increase in the number of change over; 3)

increase equipment utilization in 30%.

> Implemented a project to increase the flexibility in the workcenter with

the highest volume of color paper production. Results. 1) Triple the

portfolio of products at that workcenter; 2) creation of many innovations

to decrease change over time. Example: magnetic rod retainers, multi-

diagram adjustment of the conveyance system, static dissipative

adjustable spacers for the slitter knives, added devices to cope with the

different weight and inertia of the new products.

> Led the research and replacement of all knives used in the slitter

equipment from steel to an extra-hard composite. Results: 1) Saving of

more than US$ 500 K / year; 2) Extended the life of the knives from 7

days to 3 ~ 4 months. In some cases it can reach 12 months.

> Managed a Six-Sigma project to increase the rates of the packaging line

of the workcenter with the highest production volume of paper. New

automated machines were integrated to the line, and manual labor was

replaced. Result: 1) increase in the rates of the workcenter in 20%; 2)

headcount reduction of 30%; 3) Generated savings of more than US$ 1.5

million / year.

> Managed several projects of reduction of constraints in the packaging

line and cycle time reduction in the manufacturing equipment. Result: 1)

increase in the overall efficiency from 55% to 80%; 2) Decreased

equipment cycle time in 20%; 3) Overall rates of the workcenter were

increased in more than 70%.

> Managed projects to decrease the process change over time of the major

paper workcenters, through SMED techniques. As a result the average

change over time dropped from 125 to 9 minutes

Experience

Sr. Principal Process Engineer, Medtronic Co, CA from 2009 to Date

> Glucose Operations Principal Engineer for fabrication and assembly of

blood glucose monitoring sensors.

> Responsible for all phases of the manufacturing including production and

process development, capacity increase, cost reduction, FMEA,

characterization, Gage R&R, IQ/OQ/PQ, factory acceptance, and supplier

quality.

> Successfully managed deployment and qualification of equipment;

developed, characterized and qualified new manufacturing processes,

established performance metrics and quality specifications; and balanced

process capacity to support a high volume > $130M revenue business.

> Responsible for producing technical documentation for the implementation

of new manufacturing processes, including: Master Process Plan, FMEA,

Process Mapping, process documentation (operating procedures and training

materials), material and quality specifications, equipment

specifications, fixture drawings, and layouts.

> Keep up to date with the latest advances in technology, industry trends,

and establish networks to help identifying emerging technologies with the

potential to enhance quality and manufacturing capability of actual and

future Medtronic products.

> Develop technical specifications (user requirement specifications), lead

sourcing activities, and act as the liaison between vendors and internal

customers to ensure custom equipment and new technology meets process

needs.

> Construct business cases, project plans, charters, and capital

appropriation requests for the evaluation and implementation of new

equipment & technologies. Hold periodic meetings with projects

stakeholders. Coordinate schedule and tasks with project team and

external resources, in order to meet the business needs.

> Create process key performance and quality indicators, such as: cycle

time, takt time, line capacity, line yield, rejects rate, OEE, labor

cost, material cost, process performance (Ppk), process capability (Cpk).

> Develop and execute design of experiments (DOE) and characterization

studies based on solid statistical techniques for quality / process

improvement, technology evaluation, feasibility, and proof of new

concepts. Effectively communicate conclusions through presentations,

technical reports, test reports, and lab notebooks.

> Support technology transfer between sites. Engage in troubleshooting

activities of on-going manufacturing processes. Lead cross-functional

teams and contractors in tasks and projects. Integrate the execution of

activities with change control management. Assist with regulatory

submissions.

Sr. Process Engineer, Bekaert Special Films, CA from 2007 to 2009

> Actively supported the Coating & Lamination process with statistical

techniques (OEE, DOE, 6 Sigma, Paired Comparison, etc) with great impact

in reducing defects, variability, waste.

> Great experience with processes of mass and heat transfer, hydraulic,

pumps, drying ovens and optical film processes.

> Devised novel methods of measurement and test of optical films, adhesion

properties, and physical and thermal properties of polymers (DMA,

calorimetry, etc)

> Designed and execuioned DOEs to develop and enhance manufacturing

processes. Working on the application of engineering quality tools such

as SPC, root cause analysis, FMEA.

> Proviced statistical analysis and engineering planning for the

qualification of new products.

> Make use of analytical tools for troubleshoot the manufacturing process,

in order to find and eliminate the root cause of problems such as lines

of near impossible detection, splice scratches, optical distortion, dry

spots, contamination, and others. Played active role on the analysis and

solution of corrective actions.

> Maintained and optimized running parameters such as fluid steady flow

with real time feed back, line speed, we tension, oven temperature

gradient zone by zone, and others that greatly improved the optical and

physical properties of Bekaert special films.

Sr. Process Engineer Rogers Corporation - AZ, from 2005 to 2007.

> Provided engineering expertise to reduce process variability, reduce

defects, reduce change over time, and increase the OEE of two coating and

laminating work-centers. At Rogers the coating operation utilizes 7

different types of adhesive, applied at 9 different thicknesses, on 10

different substrates of 6 different gauges. The lamination operation

utilizes 10 types of films, and 7 types of copper.

> Optimized running parameters of line speed, tension, oven temperature,

lamination temperature & pressure.

> Provided support to the laminating process, achieving great success on

reduction of defects, variability and waste.

> Applied Shainin and Six Sigma techniques to troubleshoot the process

problems, find the root cause and implement permanent solution.

> Planed and performed series of DOE's and created mathematical-dynamic

models of the laminating / coating process, in order to provide process

optimization and solution for the major problems.

> Improved the performance of hydraulic system of fluid dispensing and

filtering system, by decreasing pressure drop, improving efficiency of

the filtering system, and providing parts of easy change over.

> Reduced variability of the finishing process (slitting & editing).

Decreased the lead time of the sequence of operations. Eliminated all

possibilities of surface defects being generated at the finishing area.

> Worked actively with R&D on the qualification of new products.

Qualification of new process parameters by performing statistical

analysis of the products under the new process against production as

reported. Ensured that new processes and products met and surpassed

specifications.

> Coordinated multi-functional teams (industrial staff, R&D, Marketing) to

develop new products.

> Starts-up new products and equipment. Managed installation,

troubleshooting initial production.

> Supervised engineering assistants and industrial staff. .

Sr. Process Engineer Eastman Kodak, Rochester - NY from 1999 to 2005

> Provide technical support to manufacturing. Help troubleshooting the

equipment. Manage and install projects.

> Provide technical support for three high volume and two custom

workcenters. Each workcenter is composed by a state of art

slitter/spooler equipment and an automated packing line.

> Create and Lead projects of process design, process improvement, and

installation of new equipment to improve the process.

> Prepare project feasibility study, form cross-functional team, create

work breakdown structure, and prepare schedule & budget. During

execution: make sure that the project follows the schedule and budget,

and work at the execution with the team to assure that the project meets

its objectives.

> Create business cases to evaluate and prioritize projects of capital to

maximize asset utilization.

> Create, participate and Lead Kaizen projects and strategies to improve

productivity, maximize performance, increase reliability, and reduce

waste in the process and in the equipment.

> Research, analyze, and start up projects of capital to improve

productivity, performance, and quality.

> Form and lead cross-functional teams to conduct projects, or to attain

short and medium term targets.

> Create, modify, and implement equipment change specifications.

> Lead cross-functional teams into process improvement, Kaizen initiatives,

and analytical troubleshooting.

> Support troubleshooting in all activities at the manufacturing

environment.

> Create performance / cost measurement tools. Track process downtime and,

through six sigma tools, prioritize improvement activity.

> Help and coordinate overseas capital projects, to allow all worldwide

sites to benefit from improvements created elsewhere.

Project Engineer Kodak of Brazil, Manaus - Brazil from 1997 to 1999

Manage projects, provide technical support to manufacturing of color paper

and health image products

Achievements

> Increased process overall effectiveness of the color paper production

from 50% to 82%, from 1997 to 1999.

> Increased production capacity of the paper finishing workcenter in 30%.

> The above projects reduced the number of working hours in 44%, while

keeping the production volume.

> Improve the quality standards of X-ray and paper sheet process to 6

SIGMA levels

> Technical Support to paper rolls, sheets, and X-ray finishing process

Automation Engineer Gradiente Electronics, Manaus - Brazil from 1996 to

1997

Provide technical support to the installation of new SMD machines for

printed circuit board assembly. Work as an automation Engineer for the

production of wide screen color TV and stereo systems.

> Developed business case comparing different scenarios for the

construction of a new manufacturing facility. The study involved cost x

benefit, capacity analysis, change over frequency and efficiency of

machines for automated assembly available in the market. Example machines

considered are: Universal through hole insertion machines, Siemens

parallel SMT assembly machines; and Fuji modular, as well as high speed

SMD assembly machines.

> Installation and start up of two new Fuji CP-6 SMT machines for the

assembly of printed circuit boards.

> Increasing manufacturing throughput of TV sets in 50% through

application of the theory of constraints.

> Increase the throughput of Stereo system production lines in more than

45%

> Development of skilled labor force to support the company in automation

technology

> Provide technical support to consumer electronics manufacturing

Software Experience

> MS Office Package, Outlook, Visio, Minitab, Matlab, Lotus Notes,

Infinity, Visual Basic.

> Design of dies, machine parts, and machines, as well as computer

simulations. Advanced user of SolidWorks, Alibre, and on AutoCAD.

Education and Certification

MS Manufacturing Management Rochester Institute of Technology,

Rochester - NY

. Alumni award

MS Mechanical Engineering Kagoshima University, Kagoshima - Japan

. Kagoshima city award

BS Mechanical Engineering Amazon State University, Manaus - Brazil

> Advanced Project Management - Medtronic - Los Angeles, CA,

> Advanced Risk & Cost management - Medtronic - Los Angeles, CA,

> Minitab Statistics - Rogers Corporation - AZ

> SHAININ Manufacturing Troubleshooting Techniques - Detroit, MI

> Six Sigma Black Belt - Kodak, Rochester, NY

> Coating and Adhesion Technology - Waltham, MA

> Language Skills: English, Portuguese, Spanish, and Japanese

> Project Management - Rochester, NY

> Advanced SolidWorks Design - Rochester - NY

> Advanced Alibre 3D Design Software - Rogers Corporation - AZ

> Kaizen Implementation - Kodak, Rochester, NY

> Programmable Logic Controllers - FESTO

> Industrial Robots - ABB

> Operating Systems: Windows XP / Windows 2000 / UNIX / Linux / Mac

> Applications: Lotus Notes, MS/Office Professional / MS/Project / S/VISIO

Contact this candidate