Injection Molding Engineer

Anthony F. Zingarelli

** ******* **.

Webster, Massachusetts 01570

E-mail: *******@*****.***

Cell: 508-***-****

Accomplishments and Skills

Injection mold processing (injection-compression, coining, decoupled molding, insert and over-molding).

Successful validation of tooling and transfer technology operation overseas. (France, Thailand, China).

GMP techniques, SOP writing and familiarity with 5S and lean practices. Successful validation of new material with large savings in tooling costs and material. Certified ISO 9001and 13485 internal auditor. IQ/OQ/PQ validation protocol. Gage R and R Studies and failure investigations. Metrology testing (Melt Index, Capillary Rheometer, Instron, and Electron microscope). Root Cause Analysis and corrective action with preventive action.

Professional Experience

12/2012 – Present

Anderson Power Products, Sterling, MA - Mid-size power connectors injection molding company which produces 10amp connectors (computers) to 700amp connectors (power industry). Anderson has 16 injection molding machines form 40tons to 360 tons.

2nd shift process/quality engineer - Ensure all product molded is within APP specs and all measurements are taken daily and documented. Perform destructive and non-destructive testing daily. Assist supervisor in processing issues in molding and update all molding documentation as needed. Prepare DMR’s (Discrepant Material Reports) for out of tolerance products and subsequent corrective actions.

6/ 1/12 to 11/ 30/12 (Temporary/Contract)

Colfax Corp. (Portland Valve), Warren, MA - A medium size company that produces all types of valves in the range of .25” up to 10” diameter used in Surface Ships and Submarines.

Quality Assurance Engineer - Used Standards under ASTM, MIL, Government, and IS09001 for compliance of all valves. Updated all documentation and wrote new procedures as needed. Prep work on all valves for inspection by Government Service Inspector (GSI) and Electric Boat (EB) Inspectors. Kit review of valves (inspection of all parts) for release to assembly. Calibration responsibility – worked with internal personnel and external vendors for upkeep and compliance of all measuring devices. Incoming inspection (Certification) of all parts for valves. ISO 9001 Internal Auditor.

7/11 to 9/11 (Temporary/Contract)

Henke Sass Wolf of America, Dudley, MA - A medium size company that repairs, rebuilds, builds endoscopes for the medical industry.

Quality Technician - Updated and rewrote ISO procedures that needed revision to ISO 13485 internal auditing. Performed root cause analysis of moisture in the endoscope. Validation of Hologic endoscopes for Smith and Nephew using endobench software and procedure. Inspection of incoming scopes bodies from Germany. Monthly Gage R and R study on inspectors. Calibrated equipment to maintain ISO 13485 compliance using outside vendors and internal QC dept.

8/10 to 6/11 (Temporary/Contract)

Putnam Precision Molding, Putnam, CT - A small injection molding company using glass/non-glass filled PEEK, Torlon, Aurum, Ultem, Ryton, glass/non-glass filled Polycarbonate and Nylon engineering resins to mold product in the consumer, automotive, defense, electronics, chemical, and cosmetic industry. Mold processing using injection molding machines with tonnage capacity from 40 tons to 500 tons, using Nissei, Arburg and Van-Dorn molding machines with single and multi-cavity molds.

Process Engineer - Initially de-bugged twelve new tools each for the Savit and NAVSEA projects and created process set-up sheets and water flow diagrams. Carried out Project Work Orders and Tooling Work Orders to debug current tooling for customer acceptance. Troubleshot process issues for insert and over-molding to drive corrective action implementation and documentation. Updated all SOP’s for ISO audit in June 2011. Trained for CMM (Sheffield’s discovery III cordax D-8 with pc-dmis program)

3/10 to 8/10 Enumerator (Part Time) - US Government Census Bureau, Central MA

10/09 to 1/10 (Temporary/Contract)

Apex Resource Technology, Pittsfield, MA - Small design engineering, manufacturing company with ISO 13485:2003 and ISO 9001:2000 ISO certifications, and Class 8 clean room molding environments. Molding medical components using Niigata Electric molding machines (85 to 150 tons) for a variety of prototype and production volume applications using close tolerance tooling for precision molding and secondary operations for materials such as PEEK, Polyurethane and PLA resins. Products include implantable screws, anchors, handle and covers, and Tissue Capture Devices.

Process Engineer - Utilized strong processing and troubleshooting skills to perform scientific molding studies. Initially de-bugged new tools and created process set-up sheets and water flow diagrams. Developed and executed IQ/OQ/PQ protocols and D.O.E. protocol tests. Update all process documentation to support manufacturing.

8/07 to 10/08

Quantum Leap Packaging Inc., Wilmington, MA - Small start-up injection micro-molding company for revolutionary hermetic LCP based semiconductor packages for electronic and computer applications. Mold processing using Sodick Plustech injection-plunger molding machines. Developed and implemented proprietary manufacturing processes using insert and over-molding process.

Process Engineer - Utilized DOE and FMEA techniques to develop high yield robust manufacturing process. Troubleshot process issues and drove corrective action implementation. Participated in new product design reviews and provided process engineering input. Wrote and implemented shop procedures per GMP’s and process specifications. Validated and debugged new tooling to produce LCP based semiconductor packages

1/06 to 7/07

Plas-Pak Industries Norwich, CT - Midsize injection molding company that produces packaging syringes from 3ml up to 750ml in cartridge barrel and syringe barrel types for the Consumer, Industrial, Animal Health and Pharma Industry. Mold processing using multi-injection molding machines with tonnage capacity from 35 tons to 650 tons, using Van Dorn/DeMag molding machines and multi-cavity molds.

Quality Assurance Engineer (Consultant/Contract) - Helped complete ISO 9001 certification on 6/27/07 by assisting in the ISO 9001 documentation process. Wrote, documented, validated and updated many Standard Operation Procedures (SOP’s) currently being used in Molding and Finishing Departments. Analyzed the root cause of customer concerns, documented processes and initiated corrective actions. Performed continuous improvement on processes, Non-Conformance review and disposition requirements. Developed corrective action procedures and preventive action procedures. Performed Gage R and R Study. Certified ISO 9001 internal auditor

10/96 to 12/05

Gentex Optics Dudley, MA - Gentex Optics produces ophthalmic lenses using multi- injection molding machines with tonnage capacity in the mid-size range, using Nissei molding machines as well as Toshiba and Cincinnati molding machines.

Support Process/Project Engineer - Validated and debugged new tooling and equipment from specifications in drawings and blueprints and using protocols in the validation process. Validated new processes and materials by way of process capability studies and IQ/OQ/PQ validation protocols. Assisted in the ISO 9001 documentation process. Wrote many Standard Operation Procedures that are currently being used in Molding/Production. ISO 9001/14001 internal auditor. Transferred optical injection molding technology to the other in Pennsylvania, Florida, France, Thailand and China). Conducted basic injection molding training as needed in injection-compression, coining and decoupled molding process. Set-up of experimental inserts for DOE (Design of Experiment) testing, molding, processing, documenting, coating, and sample gathering. Assisted in manufacturing problems and to make corrections using SPC principles as needed. Established Metrology testing (Melt Index, Capillary Rheometer, Instron, and Electron microscope).

5/94 to 10/96

Nypro Inc., (Nypromed Division), Clinton, MA - Nypromed Division Mold processing using twenty-two Ninety-Ton Netstal injection-molding machines all equipped with robots and auxiliary equipment. High volume opthalmic products molding for Vistakon a division of Johnson and Johnson.

Night-Shift Molding Supervisor - Supervised the molding operation, which include six inspectors, two Q.C. personnel and a material handler. As Molding Supervisor - Identified and resolved processing problems, while maintaining the highest quality. Identified and resolved any maintenance issues with equipment. Identified and

resolved any robot and auxiliary equipment problems to maintain production. Continuously updated and documented molding parameters.

5/92 to 5/94

PolyTop Corp., North Smithfield, RI - Mid-size injection molding company producing dispensing closures for the Cosmetic, Chemical, and Food Industry including one and two piece caps with spout in assorted sizes and colors using multi-cavity molds, both conventional and hot runner systems.

2nd Shift Molding Supervisor/ Shift Manager/ Process Engineer - Supervised the entire molding operation, which includes automation and maintenance personnel. Identified and resolved processing, maintenance and automation problems while maintaining the highest quality and safety standards to assure an excellent working environment. Worked productively with inspectors, Q.C. technicians, maintenance personnel, automation personnel and material handlers. Continuously updated and documented of molding parameters.

7/84 to 5/92

Norton Company, High Performance Ceramic Division, Northboro, MA

Senior Research Technicians for the Injection Molding Project - Injection Molded simple and complex parts for automotive and electronic applications using High Performance Ceramic materials. Mixed and compounded using a two roll mill and formulated for extrusion into pellets. Wrote Standard Operating Procedure for material preparation and injection molding of this material. Prepared material for molding cleaning, sintering and other unique processes. Recorded, analyzed and documented all work. Instructed co-workers on projects and use of equipment. Care and maintenance of all equipment.

11/80 to 7/84

Carl Gordon Industries, Worcester, MA - This company made polystyrene material for the injection molding industry.

Physical Testing / Quality Assurance Technician - Established the Physical Testing Laboratory. Updated and revised test procedure methods. Trained and supervised Quality Control Inspectors. Performed physical tests on incoming raw material, finished product material and regrind material. Used a variety of equipment including: Instron, Melt Index, Newbury Injector Molder, Izod Impact Tester, and various scales, weights and ovens.

Education

University of Lowell - Bachelor of Science - Plastic Engineering

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