Engineer Manager

Gary D. Millsap M.B.A. - Engineer

East Kingston, NH Email: ***************@*******.***

Cell: 719-***-****

Executive Summary

I am a Hands On Manager and Engineer with over 20 years of experience in

Process Engineering & Development, Quality Management and Production

Management

Project Management experience: at $500k levels, in scale up from lab to

pilot to full commercialization; creating cost effective manufacturing

processes while meeting quality, cost, and timeline requirements.

Quality Engineer/Manager: with experience with Design Review, ISO-9000,

DOE, SPC, and Lean Manufacturing.

Applications Engineer, working with field sales to establish

customer/market application requirements, improving quality of existing

products, coordinating customer-initiated projects.

Manufacturing Management: experience in managing subordinate engineers,

technicians, and production operators: hiring, training, coaching, and

mentoring to develop individuals into key contributors.

Ceramic Engineer with a keen understanding the Material Science of

Ceramics, Metals, & Plastics and the manufacturing processes of the same.

Statistician: Education in Applied Statistics, resulting in an ability to

study and solve complex manufacturing and quality problems

Engineering and Manufacturing Expertise

. Experience with Forming Processes:

o Injection Molding, Extrusion, Net Shape Forming of Ceramics,

Roll-Compaction, Tape Casting, Green Machining. Thick Film

Printing on Ceramic Substrates

. Machining/Grinding:

o Lapping, Centered & Centerless Grinding, Small Hole

Lapping/Honing, Surface Grinding, Jig Grinding,

Water/abrasive Jet Machining, Ultra-sonic, and "High

Precision" Grinding: tolerances to sub-micron and associated

metrology.

. Ceramic Body formulation:

o Alumina, Zirconia, Silicon Carbide, Cordierite, Glass, and

Glazes.

. Ceramic Material Batching:

o Milling, Spray Drying, Slip Rheology

o Kiln Firing: Small Periodic to Large Tunnel Kilns, Air or

Atmosphere Control.

o Wet Chemical Processing of Ceramic Powders

o Freeze Drying

. Design Engineering:

o Experience in Designing Complex Molds, Fixtures, and Tooling.

Quality Engineering

. American Society for Quality, Certified Quality Engineer CQE

. American Society for Quality, Certified Quality Auditor CQA

. Implementation of "Real Time" SPC and respective software on the

manufacturing floor

. Quality Auditing, Internal and Supplier

. ISO-9000

. Design Review

. DOE

. FMEA's

. Lean Manufacturing

. Change Agent

. Manager of Quality Department

Education & Certification(s)

M.B.A., Southern New Hampshire University, Manchester, New Hampshire

B.S. Ceramic Engineering, University of Missouri - Rolla, Rolla,

Missouri

M

Graduate Certificate Applied Statistics - University of New Hampshire

(Durham)

Six Sigma Green Belt

CQE: American Society for Quality - Certified Quality Engineer

CQA: American Society for Quality - Certified Quality Auditor

mm

L3 Communications Wilmington, MA 4/2011 to present. Title: Ceramic

Division Manager

I am the Department Manager of Ceramic Engineering and Manufacturing.

My department produces very complex and often highly tolerance shapes

from Silicon Carbide ceramic materials for internal use within L-3COM.

The Ceramic Shapes include mirrors and chassis used for Space and

Aerospace Optical Systems. The Optical Systems are very complex

devices and truly "cutting edge" technology. The programs often

involve several million dollars for the optical system, for which I'm

typical responsible for ~$250K per program to Engineer and Manufacture

the complex shapes from Silicon Carbide. Through 2 direct reports and

we accomplish 100% manufacturing equipment Up-Time and 100% On Time

delivery to meet the strict schedules given for these programs.

Depending on the program requirements, I have a number of indirect

reports including Design Engineers, Optical Technicians, and

Machinists which I manage to accomplish the tasks of designing molds,

performing functional testing and analysis, fabricating molds and

fixtures.

Accomplishments so far:

1. Increased mirror manufacturing capability from 16" diameter to

70" diameter. This has generated new market opportunities at L-

3Com for Silicon Carbide to be used in large optical systems,

replacing glass or beryllium with the performance advantage of

Silicon Carbide Ceramics.

2. Improve jointing or welding of ceramic joints to eliminate

structural failures and increasing chassis strength

3. Improved mold design of complex shapes, allowing for manufacture

of larger shapes and lower mold cost.

4. Improved ceramic material. This increases the optical

performance of the silicon carbide ceramic material properties

and reduces subsequent processing costs for the mirrors.

Saint-Gobain Advanced Ceramics Colorado Springs, CO (3/2007 to 4/2011)

Title: Plant Production Manager Advanced Ceramic Products

I was the Production Manager manufacturing Structural Zirconia Ceramics

used in canning dies, oil and gas wells, and electrostatic

applications. My responsibilities included meeting schedules, quality

requirements, and cost constraints. I was also responsible for Quality

Management and maintaining ISO-9000 certification for the location.

Finally, I had quote responsibility for current and new products and

customer contacts. Manufacturing Process involves Wet Milling and

Spray Drying, Dry pressing, Green machining, Sintering and HIPing, and

Precision Grinding to micron tolerances. I manage a 33 person

manufacturing operation, with 26 direct Reports.

Angstrom Medica, Inc Woburn, MA (3/2003 to 3/2007) Title: Director of

Process Development

Angstrom Medica was a start-up venture based on patented bioactive

material technology developed at M.I.T. for orthopedic applications.

The trade marked material NanOss developed by the team at Angstrom

Medica is Nano-Crystalline Hydroxyapatite which mimics the same

material of bone. After a number of successes in clinical trials and

rounds of venture funding, Angstrom Medica was purchased by Pioneer

Surgical; yielding considerable value for the ground floor investors.

Please search "NanOss" on the web to learn more about the unique

material we developed.

I joined Angstrom Medica at the "ground floor" as a technical expert

in processing ceramic materials. My responsibility was to take

literally a "Bench Top" process developed at M.I.T. to a pilot level

manufacturing process producing a variety of orthopedic products thru

510K submission and approval. I accomplished this through hiring a

several Engineers and Scientists and developing a super dynamic team.

On a weekly basis I mentored team members on their assignments and

personal development. My skills of creating strong group cohesion and

member interdependence were relied upon heavily and perfected. The

challenges required a high degree of creativity and diverse technical

knowledge.

We developed 100% dense Nano- Hydroxyapatite of exceptional high

strength and osteoconduction for orthopedic applications. NanOss was

the first Nano Technology material to receive FDA approval.

We demonstrated NanOss can be used for the "Base" material in a

number of Orthobiologics. Many of these are demonstrated at Pioneer

Surgical's website.

The Angstrom Medica team was successful in raising $3.7 million

through Series B private stock sale and nearly $2 million in NIH and

NSF grants.

Reports: 6 Engineers and Scientists

UNISON INDUSTRIES, Inc. Norwich, NY (1/2002 to 3/2003) Title: Senior

Ceramic Engineer

I was responsible for the steering ceramic expansion program to

manufacture alumina ceramic insulators for turbine engine applications.

Within a short time frame I solved ceramic dielectric strength

problems with the ceramic, which resulted in a major increase in

business volume for the ceramic department.

I established viable outsourcing for batching and spray drying

Alumina ceramic bodies resulting in reducing costs and removing

internal capacity constraints.

I gained manufacturing experience in metallizing, plating, and

brazing ceramic components.

OSRAM/Sylvania Exeter, New Hampshire (1997 to 2001) Title: Principal

Engineer

I developed Ceramic Injection Molding and Extrusion manufacturing

processes for the production of transparent Alumina ceramic lamp

components.

I managed programs through cross-functional teams consisting of

outside vendors, engineers, and technicians.

Responsible for project management, including scale-up, engineering,

machine design, mold outsourcing, purchasing, installation, and all

significant aspects of the Ceramic Injection Molding program.

I developed an expertise for ceramic component molding at prototype

scale to full-scale manufacturing; 250,000 per week.

I created new mold designs and tooling and developed key contract

agreements with outside tool and die shops.

I developed a unique in-line microwave drying process for the drying

of extruded ceramic tubes.

COORSTEK Grand Junction, Colorado (1980 to 1997) Title Engineer IV

Intensive "hands on" experience acquired principally at the Senior

Engineering Level, in the manufacture of components made from Advanced

Ceramic Materials. My career emphasized Ceramic Engineering, Quality

Engineering, and Process and Product Development. For several years I

was the supervisor of the Process Control/Quality Assurance

Department. The 9-person department consisted of technicians and

engineers, and assured the product quality of the ceramics

manufactured.

Additionally, the Process Control department was responsible for

performing many analytical tests on the ceramic raw materials and

fired ceramic properties. These tests included X-ray Diffraction, DTA,

SEM, MOR, Hardness, Surface Finnish, Surface Chemistry, Grain Boundary

Chemistry, Powder Particle Size, and Fired Grain Size. I trained

technicians in the preparation of samples and performing these

analytical tests.

I gained several years of experience with machining Alumina and

Zirconia parts to micron tolerances. As a Process Development

Engineer in the manufacture of fiber optic ferrules and fluid metering

valves, I developed ceramic grinding processes and metrology to

achieve 6-Sigma capability of +- 1 micron.

References: Available Upon Request

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