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Converting Engineering

Signal Mountain, Tennessee, 37377, United States
January 31, 2018

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*** ****** *****, ****** ******** TN 37377

Phone 423-***-****, Mobile 423-***-****, Email:



Acquired through over twenty-five-years of Design Engineering and Engineering-for-Manufacturing practice and management.

Hands-on Process Development, Machinery Design and Building, for converting and special process equipment. Able to identify the appropriate technologies to create unique, cost-effective processes and equipment solutions to challenging converting and specialty web-based manufacturing requirements. I provide solutions that address both the specific product and the level of market participation desired.

Generate and supervise the generation of all Engineering Materials required to manufacture, build, and maintain complex converting machinery, including complete manufacturing lines. Blank-sheet-layout design, Detail, Assembly Drawings and Bill-of-Materials.

System Trouble-shooting / Root-cause analysis of manufacturing processes with a TPM focus. I am known for finding and addressing manufacturing deficiencies with simple, inexpensive solutions.

Process Optimization performed through effective continuous improvement and process control. I have consistently demonstrated the ability to increase machine through-put by individual process (task) optimization, task quantification, and total system (line) balancing. Enhancing manufacturing and quality, while decreasing material and machine-time wastes. Through reducing product variance to the established Quality Standard able to maintain the reduction in variance through task quantification, implementation of SOP’s, and operator training.

System and component retrofit. Modification of existing equipment to fulfil special requirements; increase through-put, or simply test a new process or manufacturing theory.

Extensive experience using aqueous, waterborne, solvent-based, and UV coatings

Combining multiple substrates for complex products using Adhesive Lamination, Extrusion Lamination, Heat-Sealing, Embossing / De-bossing, Diecutting with Matrix removal, Slitting and Rewinding.

In-depth process design experience with high-speed dispense and pneumatic control valves, extrusion systems (both heated and cold processes) for adhesives or special web coatings. I have extensive process experience using automatic-type HVLP & LVLP atomization devices (for automated coating); flexographic coating application, and high-speed electronic application controller design.

Generation of Product Manufacturing Specification, Standard Operating Procedure, and Process Validation documents for ISO certification, FDA registration, or GMP compliance.

Generation of Project Justification Analysis, Project Budget, and Project Timeline, Final Product Unit Cost Analysis.

Card and Label attaching expertise. Single and multiple machine configurations

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Pump, Meter, and Dispense system design expertise. Including those for high-viscosity suspended solids, emulsions, and fragrances.

Perform effective out-sourcing of raw materials, machine parts, and equipment, employing JIT procurement methodology.


Employer: Biomedical Innovations, a company that produces medical devices, using complex web-based manufacturing platforms for their manufacture.

Position: Sr. Process Engineering Consultant, a contract position


Assigned Engineering tasks:

Part and Chad Removal -- Provided ejection and collection solutions for situations when parts were too small and would either stick in the rotary die or in the take up matrix. Eliminated the need for operators to reduce web speed, so as to stay ahead of the operation.

Improved die cutting and make ready efficiency for difficult applications where operator were struggling with make ready waste and die cutting consistencies.

Vacuum Pickup System and pneumatic-based chad stripping -- Designed a system that, using extreme low pressure vacuum air, strips tiny pieces from the die cylinders. Made recommendations for a collection system for both the chad and waste matrix streams.

Dual Accumulator for Pick and Place on the Delta ModTech equipment - Provided fine tuning and capability analysis in order to expand into applications where pausing the web, place a component or part, and then index accurately to the next location.

Plow Folding - Provided flow folding options and strategies for various products on multi-web converting lines in order to expand the business for both paper and film based components.

Rotary debossing or thermoforming -- Provided insight for thermoformed and cold formed solutions for films .

Stacking and Piling-- Provided avenues for a receding pile stacker and or a suitable stacker that provided easy to handle stacks to reduce or eliminate handling and the need to count off the production line.

General Operation Qualification Focus – For the current products produced, provided a genuine focus on process improvement, analyzed the current processes and fine tuned them for better performance.

Provided material and product flow analysis for general manufacture and material handling.

Employer: TrendCentric Inc.

Duration: 12/13 to 06/16

Title: Manufacturing and Process Engineer/ V.P. Manufacturing

From a start-up position, I established and validated all processes/procedures, materials, and equipment. Created a basic quality system to manufacture a revolutionary cosmetic product, which involved board lamination, die-cutting, and screen printing of cosmetic materials and adhesive.

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Employer: Orlandi Fragrance Products Inc. (fragrance and cosmetic sample manufacture)

Title: Research and Development/ Consulting Engineer

Duration: 3/06 to 5/13

An FDA registered (for Drug Packaging and Cosmetic Formulation), ISO certified, and GMP compliant manufacturing facility.

Duties: New Product Research and Development, converting machinery process design and implementation, process improvement, and project management. Developed a fragrance sample package that used only FDA direct skin contact materials using standard web converting equipment. Provided in-depth quality system support. Performed internal and external (vendor) quality and operational audits for sanitation and equipment reliability. Played a key role in assisting the Director of Quality Systems in establishing, implementing, and maintaining the quality management system. Prepared Corrective Action Plans, S.O.P’s, and performed Validations of new procedures to address Manufacturing and Quality deficiencies.

Researched, sourced, and instituted a clean room for use in incoming quality sampling of incoming customer and vendor supplied bulk materials. Instituted sampling procedures and performed validations for same.

General Operation Qualification Focus for the current products produced. Provided process improvement, analyzed the current processes, and fine tuned them for better performance and waste reduction.

Provided material and product flow analysis for general manufacture and material handling.

Employer: Revlon Consumer Products

(Manufacturing and Packaging Facility. FDA registered for Cosmetic Formulation, ISO certified, and GMP compliant manufacturing facility.)

Title: Engineering Supervisor, a contract position

Location: Oxford NC, Revlon’s main manufacturing and packaging facility

Duration: 7/05 to 1/06

Job duties: Plan and supervise the operation of Equipment Engineering on the 3rd shift.

This position entailed the formulation, planning, and execution of manufacturing line modifications and machine maintenance issues for a 1.5 million sq. ft. facility. My charge was the Equipment Engineering staff and Electrical / Electronic Technical and Maintenance staff. I was responsible for up to twenty direct reports with responsibility of up to eighty manufacturing lines. Performed CMMS system data entry.

Employer: Self-employed, 2Ce Solutions

Duration: 6/2002 to 7/05

Location: Various short and long term projects.

Job duties: I provided innovative solutions that enable Label, Flexible Packaging, Converting, and Direct mail marketing companies to take their product to the next level. I provided simple yet viable solutions to complex manufacturing requirements as well as product enhancements that grew product value and margin.

Employer: Arcade Marketing, Inc., (fragrance and cosmetic sample manufacture)

Title: Senior Research and Development Engineer (product & process Development, production support)

Location: Chattanooga, TN

Duration: 11/1997-06/2002

Job Duties: Using print-based manufacturing platforms (commercial off-set and flexographic) Arcade has grown to the position of global leader in the production of fragrance, cosmetic, and personal care sample devices, manufactured by various complex web-converting methods, using paper, film, foil, and non-woven materials. An FDA registered (for Drug Packaging and Cosmetic Formulation), ISO certified, and GMP compliant manufacturing facility.

Duties: Interacting between Client-Customers (both domestic and international), Sales and Manufacturing, my position entailed all process development, equipment design steps necessary to evolve new products from conception through manufacture, including quality standard generation, production training and support.

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Arcade continued:

Chaired the Engineering Team, a cross functional group comprised of all department heads and technical leaders. We implemented new production lines and process improvement initiatives. I worked extensively with sales, marketing, executive, and clients in new product development and legacy product enhancement/ support.

Supervised exempt, non-exempt, and hourly employees as required.

During my employment period, we added approximately 20 new sampling technologies, adding 47% to the gross domestic sales base.

Employer: Self-employed

Title: Freelance Converting Engineering Consultant

Location: Chicago IL

Duration: 06/1993-11/1997

Job Duties: Various contract projects entailed Converting Process and Equipment Design Engineering, Upgrade, and Installation Engineering for printers and O.E.M. equipment manufacturers.

Employer: NWF Industries, Inc, privately held by the former owner of Arcade.

Title: General Manager, Engineering & Manufacturing.

Location: Chattanooga, TN

Duration: 04/1990-06/1993

Job Duties: Designed and manufactured specially-engineered converting equipment, and provided process consulting services for niche-market printers and converting companies .

Manufactured a revolutionary Rotary Cutter that had a ten-minute make-ready time, air-type chip removal, and on-the-fly chip size adjustment, awarded (3) U.S. and International Patents.

My position entailed responsibility for all Design Engineering and Manufacturing Operations. This was a hands-on position--not just managing.

Employer: Arcade Printing, Inc., div. Thompson Group Holding Co.

Title: Plant Engineer/ Director of Engineering

Location: Chattanooga, TN

Duration: 02/1987- 04/1990

Job Duties: Provided plant-wide Engineering & Maintenance Management. I performed process design engineering for all special projects. Supervised the installation and commissioning of two, new manufacturing platforms. Includes the AD-A-Scent Program, wherein small fragrance samplers were attached nationally to mass market K-Mart and Walgreen's sale inserts Sunday newspaper supplements.

Designed, built, and successfully tested an off-line, pouch-forming, heat seal machine that produced true, wet-fragrance samplers at 525 feet per minute.

During my employment, 2 new, hi-margin product lines were added, which resulted in 27% growth in gross domestic sales.

Employer: Custom-Built Machinery, Inc., privately held

A Converting Equipment O.E.M.

Title: Project Engineer/ Converting Machinery Design Engineer

Location: York, PA

Duration: 05/1982-02/1987

Job Duties: Designed high and low speed converting equipment for the printing industry: in-line paper finishing systems; die-cutters, flexographic pattern gluers, rotary plow-folders, rotary sheeters,

Fragrance slurry applicators. Additionally designed three-knife trimmers, quarter-folders, high-speed feeders, add-a-card attachers, tucker-folders.

Performed layout, design, and detail engineering tasks.

Supervised subordinate engineering staff members and installation personnel.

During my employment period, world-wide sales growth exceeded 60%

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U.U. Navy, attended various jet engine repair schools

Attended Penn State School of Engineering, BSME curriculum, for approximately two years G.P.A. 3.6.

I left collage to accept Jr, Designer position at Custom Built Machinery.


Mr Roger Starett, Business Unit Director, WS Packaging Group 919-***-**** (mobile phone)

Mr. Greg Renn, Owner, Techni-Web, Inc., Manufacturers of In-Line Finishing Equipment 815-***-****

Mr. Douglas Whitaker, Sr. Vice President, Orlandi Laboratories 423-***-****

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