Engineer Engineering
Resume:
JOHN P. SULLIVAN
Lake Mary, FL 32746
***********@*****.***
SUMMARY OF QUALIFICATIONS:
Subject Matter Expert in all plastic, textiles, metal, electronics and most fabrication manufacturing processes
Diverse industry experience: Aerospace, Medical, High volume Consumer Goods, Electronics
Exceptional mechanical aptitude
Expert in creating & maintaining sustainable sourcing partnerships through development of key vendors
Effective in both technical and managerial problem solving
PROCESS EXPERTISE INCLUDES:
Injection molding, blow molding, vacuum forming, extruding, rotational molding, painting, textile manufacturing, stamping, forming, printing, grinding, lapping, welding, plating, die casting, investment casting, compounding, bottle filling, electronic assembly, hand soldering, CD replicating, packaging, printing, card manufacturing, foam fabrication, mechanical assembly, CNC machining, surface mount technology (SMT) and through hole soldering, printed circuit board (PCB) fabrication, tube forming, sheet metal forming, extruding, composite laminating, & tooling, lapping, grinding, cleaning, packaging, material handling, brazing, pad printing, sonic welding, circuit card nassembly (CCA), cable and harness assembly
WORK EXPERIENCE:
2012 – Feb 2018 Oakley, Inc. (Luxxotica) Foothill Ranch, California
Staff Engineer
Develop new processes, design fixtures, and qualify equipment to support manufacturing lean initiatives.
Responsible for improving operations of manufacturing by reducing scrap, minimizing labor, and improving
operational efficiency. Reduced scrap from scratched parts resulting in a $12.5MM annual savings. Improved the lens coating process to reduce consumable spend by $1.5MM annually.
2007 – 2012 Oakley, Inc (Luxxotica). Foothill Ranch, California
Supplier Quality Engineer
Support supplier sourcing and manufacturing activities for all Oakley Rx prescription frames, logo icons & electronic products. Represent quality on new product introduction programs. Work with internal teams and international suppliers on quality issues, performance, and improvement processes. Investigate causes of quality and yield issues. Improve supplier quality performance for assigned suppliers via Quality Plan implementation. Develop positive relationships and work closely with Global Sourcing. Act as QA representative on the material review board (MRB). Review and approve protocols, procedures and specifications. Perform supplier audits for compliance.
05/04 – 02/07 Columbia Medical, Santa Fe Springs, California
Engineering Manager
Created original designs for new products that resulted in increased sales of 350%. Developed mechanical design concepts and mechanical verification prototypes. Managed outside design and manufacturing resources. Directed prototype builds, sourced and qualified new suppliers for unique processes, articulated the voice of customers to new product design teams. Designed and developed original manufacturing equipment for new products and processes. Set up production area. Managed new production start up. Managed federal regulatory approval for new products.
08/02 – 02/04 Acco Brands, Inc., Corona, California
Advanced Manufacturing Engineer – Integrated Design & Engineering (IDE)
Represent manufacturing on new product teams consisting of design, engineering, marketing and customer service. Evaluate new and existing products for manufacturability and cost optimization, while supporting successful product launch and manufacturing execution throughout internal and external resources. Primary liaison between engineering and outsourced partners on technical and/or process related issues. Proposing and evaluating manufacturing process alternatives for new product designs with regards to cost, quality, reliability, risk and product design esthetics. Perform product cost analysis and communicating results to a cross-functional new product team.
01/02 – 07/02 Mattel, Inc. El Segundo, California
Staff Engineer – Advanced Manufacturing Engineering
Provide industrial and process engineering support to Mattel plants and vendors. Conduct training sessions in plant layouts, assembly line set up and balancing, and in new processes and equipment start up. Assist plants in debugging products and improving assembly processes. Identify and implement cost improvement opportunities at all Mattel manufacturing and distribution facilities through reductions in key cost component areas (material, overhead, direct and indirect labor). Initiate energy savings programs in manufacturing plants. Define and implement improved material handling applications for plants and vendors. Drive plant layout changes to improve flow, throughput, reduce WIP inventories and space requirements. Participate in product design review for manufacturing improvement through DFM (design for manufacturing) analysis and cost justification.
1994 – 2002 Mattel, Inc. El Segundo, California
Manufacturing Engineering Manager
Responsible for engineering and project management aspects of product development, sourcing, start up, and production of a $750MM global vendor operations group. Direct design effort relative to the manufacturability, quality, safety and cost of the product resulting in a PPV savings of $2MM+ annually. Conduct manufacturing review meetings. Oversee engineering pilots for manufacturing process development. Guide the development of product tooling and debug. Review tool capacity for the ability to support full production. Define labor requirements. Evaluate vendor’s capacity in all manufacturing areas to meet scheduled demands. Engineering liaison support for a network of vendors in North America, Europe and Asia. Provide technology training as necessary to vendor personnel in support of product manufacturing process development.
Process Expertise: injection molding, blow molding, vacuum forming, extruding, rotational molding, painting, sewing, stamping, printing, grinding, lapping, welding, compounding, bottle filling, electronic assembly, CD replicating, packaging, card manufacturing, foam fabrication, mechanical assembly, CNC machining, soldering, surface mount technology (SMT), printed circuit board (PCB) fabrication,tube forming, sheet metal forming
1993-1994 Andis Clipper Inc., Racine, Wisconsin
Sr. Process Engineer
Implemented process improvements for all assembly and fabrication for a high volume commercial manufacturing operations. Designed tooling and fixturing operations. Developed new processes to improve manufacturing yields and reduce repetitive motion injuries. Wrote material and test specifications. Evaluated new equipment for material handling, assembly, and fabrication applications. Responsible for equipment maintenance and repair.
1991-1993 Magnavox (Aerospace Division), Torrance, California
Sr. Manufacturing Engineer/Project Engineer
Evaluated field failures to implement engineering product design and process changes. Performed failure analysis on electrical and mechanical assemblies to improve product reliability. Identified and corrected design and process defects to facilitate improved manufacturability. Validated new equipment, materials, and processes to implement operational improvements. Documented all hand and machine processes for mechanical and circuit board assembly. Conducted key vendor assessments and certified vendors. Performed MRB (Material Review Board) activities and advised Mechanical Design Review Board. Interfaced with customers and service representatives to isolate product defects and implement corrective action plans. Provide liaison engineering support for all upgrades and retrofits. Engineering production support for all circuit board assembly (CCA), harness assembly, SMT and through hole production.
1988 – 1991 VTEK Aerospace, Gardena, California
Engineering Manager
Performed failure analysis on electrical and mechanical assemblies to improve product reliability. Redesigned products to reduce costs, enhance performance, and improve reliability. Evaluated new equipment, materials and processes to implement process improvements. Interfaced with customers and service representatives to isolate product defects and implement corrective action plans.
1985-1988 Hughes Aircraft, El Segundo, California
Process Engineer
Performed process engineering support for electronic fabrication and assembly, including circuit board and harness fabrication, surface mount, through hole, hand assembly (CCA), and electromechanical assembly.
Supported major plant modernization project by coordinating and developing facility layouts for a new centralized/automated storeroom. Performed time and motion studies for work measurement analysis, variance analysis, methods improvements, cost reductions and line balancing to optimize manufacturing operations. Performed project engineering activities for the F-14 development and production programs.
EDUCATION:
University of Wisconsin, Platteville, Wisconsin
Bachelor of Science, Industrial Technology, Emphasis in Materials & Processes,
Minor in Psychology
Certified in MTM-UAS work measurement techniques
PROFESSIONAL AFFILIATION:
Institute of Industrial Engineers, Los Angeles Chapter
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