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Injection Molding Engineer

Gilbert, Arizona, United States
November 24, 2018

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

Gilbert, AZ 85296


I am looking for a position where I can apply my Black Belt and management skills to failure analysis, fault reduction, process improvement, and research and development opportunities.

W.L. Gore Phoenix, AZ 02/18 – Present

Experienced Process Development Engineer

• Write and execute validation protocols on new equipment in accordance with FDA Medical device 21CFR820 requirements and ISO13485 requirements. Document and record validation protocols and reports in PLM agile Oracle-based business/quality system.

• Drive improvement projects with the injection molding process. Completed injection molding training from AIMI focusing on scientific injection molding and troubleshooting. Lead manufacturing studies to test the interaction between various variables (small scale DOE).

• Write NCR’s, SMR’s, and CO’s to reduce non-conformances and develop new processes in accordance with FDA class 3 regulations.

• Capability studies for UV cure bonding processes to proactively determine degradation of UV bulb.

• Created VSM for Catheter assembly line including: induction coil catheter transition bonding, UV bonding, and various other assembly procedures, identifying bottle neck and TAKT time requirements to meet production demands.

Sargent Aerospace Tucson, AZ 08/17 – 02/18

Engineer III

• Led efforts to establish Kan Bans, while improving process flow. (Increased throughput by 25%).

• MBOM creation and updated master router operations.

• Led cross functional process improvement teams and led waste reduction projects.

Permobil Corporation (Manufacturing TiLite Wheelchairs) Pasco, WA 1/15 – 08/17

Senior Industrial Engineer

• Developed new tooling and documented new processes for new product introduction.

• Managed Kaizen events to improve process flow.

• Utilized value stream mapping and calculated Takt time to create a balanced production line.

• Managed engineering and maintenance departments with up to 6 employees. Responsible for Tool design and prototyping.

• Established maintenance schedules and worn part replacement processes. (Reduced production downtime by 15%).

• Managed the installation and validation of new industrial equipment. Documented validation results and process instructions.

Smith & Nephew Corporation (Medical Device Design and MFG) Austin, TX 11/13 – 1/15

Senior Process Development Engineer

• Developed new technologies and manufacturing processes

• Validated and implemented time-controlled hot air tools used to melt solder sleeve. Replaced a low yield crimping process.

• Developed ideas through Solidworks.

• Wrote and executed IQ, OQ, PQ requirements.

• Documented protocol reports in Oracle quality system in accordance with FDA requirements.

• Improved UV cure and solvent bonding processes.

Emerson Corporation (Micro Motion Division) Boulder, CO 5/06–11/13

Manufacturing / Industrial Engineer III

• Organized teams of up to 15 associates to consolidate manufacturing from multiple buildings into one building.

• Led LEAN initiatives, eliminating waste in transportation. This project reduced $100,000 in excess material handling and defects.

• Set up new efficient cellular manufacturing lines to increase capacity by 15%.

• Audited all manufacturing processes.

• Implemented new statistical process controls in the coil shop to reduce product variation by 30%.

• Co-created graphical assembly guides with engineers and operators to improve, standardize, and “poky yoke” (mistake proofing) the manufacturing process.

• Organized PFMEA’s to improve product releases.

• Led workstation consolidation projects, reducing WIP inventory by 10%, cycle time by 10%, and rework by 15%.

• Worked across departments to streamline the manufacturing processes and improved the overall product quality by 10% over 1 year.

• Developed worldwide solder training for all Micro Motion manufacturing locations. Taught soldering classes in US and Mexico.

Brigham Young University / BD Medical Provo, UT 8/05-4/06 (BD Medical)

Senior Project Research

• Worked with a team of 7 engineers from BYU on a project for BD Medical to design and build a closed catheter system that precludes blood exposure.

• Developed and manufactured a catheter that uses no flash.

• Designed and built a venting system for evacuating air out of the catheter line, eliminating the possibility of blood exposure.

• Patent received. USPTO US2007/080468.

• Computer Skills:

CAD: Pro Engineer, Solidworks, AutoCAD, Microsoft Office suite, Microsoft Projects, Oracle-based Agile systems, and UniPoint.

• Relevant Skills:

• Excellent problem solver.

• Works well with people.

• Excellent mechanical, visualization, and development skills.

• Knowledge of process improvement tools: LEAN manufacturing, Taguchi Loss function, CP, control charts, Pareto diagrams, flow charts, CPK, and creating Value Stream Maps.

• Teaching quality improvement training courses about Six Sigma tools to improve the manufacturing process.

Bachelor of Science in Manufacturing Engineering in April 2006 from Brigham Young University.

Patents Achieved:

USPTO US2007/080468 “Extravascular system in-line venting”, Austin, J; Jacobsen, J; Henderson, S; Evans, T; Funk, S; Condie, S; Smith.

Six Sigma Black Belt Certification - April 19, 2006 - Pacific Rim Business Review Inc. – Tony La Turner (Master Black Belt)

Injection molding training - August 22, 2018 - American injection molding institute. – Dave Rose (AIMI Champion)


(2017) Established flow and Kan Ban for submarine hydraulic valve assembly increasing throughput by 25%.

(2015) Assembly Line = Increased throughput by 10%.

(2012) “T-sensor Pre-Diagnostic Testing” = Drove scrap down 90%.

(2011) “D-sensor Pickoff Failure Elimination” = Eliminated a 5% warranty return rate.

(2010) “Induction Braze Re-Design” = Established PLC controlled induction chamber to eliminate reoccurring scrap.

(2009) “MVD Lid scrap reduction” = Safety concern elimination and 80% reduction in scrap.

(2008) “F-sensor LEAN Efforts” = Increased productivity by $12 million dollars/yr. Cut floor space to 1/3, 50% WIP reduction.

(2007) “Cart Improvement” = Elimination of physical damage high bar by 50% through the application of new transportation technology.

(2006) “Outstanding performance” recognition for completing 15 projects in my first 15 months at Micro Motion.

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