Project Manager Engineer
Resume:
Robert M. Castillo
Kissimmee, FL, 34746
******.******.********@*****.***
Objective: To improve the bottom line performance of any corporation by applying best practices in
Manufacturing/Product Engineering, Project Management, and New Product Introduction.
Summary of Qualifications: Engineering Project Manager with over 12 years of Manufacturing
Engineer experience in complex/commercial Electro-Optical-mechanical systems. Manufacturing
Engineering experience with interferometers, industrial lasers, and high speed telecommunications
systems products. Engineering Project Management experience in new product introduction and in
developing robust processes that enable product quality, yield requirements and exceed product lifecycle
development milestones and targets.
Professional Experience:
MKS Instruments -NPI Project Manager - Methuen, MA January 2008-3/25/2014
• Lead the development and execution of a complex Electro-Optical-mechanical systems from
prototype to production. Managed activities for Design Engineering, Manufacturing Engineering,
Test, Reliability, Service, Production, Quality, and other groups.
• Conducted multi-divisional DFX project in support of new continuous air monitoring system (using
FTIR technology). Responsible for implementing the mechanical, optical, electrical and test
changes resulting from the DFX effort which resulted and in 85% increase improvement in
production throughput and 58% in product reliability.
• Conducted DFMEA and PFMEA on subassemblies and production processes to better optimize
the product design and its manufacturability.
• Developed, Justified, and Managed a $500K Capital Budget for Manufacturing Engineering.
• Successfully managed the production and on-time delivery of $2.6M in customer orders of early
development product.
• Reported New Product progress and risk updates to cross functional teams as well as Company
Officers on a regular basis.
• Coordinated Pilot and Qualification builds for New Products, both in house and with Contract
Manufacturers.
• Managed material and inventory for early phases of the project and worked closely buyers and
planning to properly transfer these into production environment of the MRP system.
• Created overall and component Process Flows, Value Stream Map (VSM) and PFMEA for new
and existing products. Use these plans to redesign entire 100,000 Ft2 manufacturing and clean
room facilities-including detailed 3D cell layouts.
• Responsible for creating product structures, defining service plan and FRU, process flows,
product routings, BOM, ECOs, and initial product setup in PLM & MRP systems.
• Provided leadership in data driven, root cause analysis to resolve technical problems and
continuously improve the existing production methods to remove waste, mistake proof and
optimize the process.
• Managed the Design and acquisition of production tooling and test equipment from contractors.
• Managed and mentored multiple Manufacturing Engineers (indirects).
• Provided Product Costing Models and Labor Estimates and validated/adjusted them in actual
prototype runs.
• Created Work Instructions and conducted process training for all new assembly builds.
• Performed failure analysis and implemented corrective actions on all pilot builds.
Coherent Inc. - NPI Manufacturing Engineer - Bloomfield, CT 10/ 2006 – 01/2008
• Planned and coordinated Prototype & Pilot product builds of the new industrial laser products
which lead to the successful launch to evaluate the design and processes in preparation of full
scale production release.
• Supported the development organization by leading the manufacturing effort to define and drive
design for manufacturing with the goal of reducing assembly and test time, and increasing the
overall product reliability.
• Responsible for providing design for manufacturing feedback as well as root cause analysis
reports to the R&D development team which resulted in a more reliable and easier to
manufacture product.
• Responsible for setting up production stations and process flow for the new product
• Responsible for developing and designing new tooling, fixtures, assembly drawing and methods.
• Worked closely with quality and manufacturing department to develop, coordinate, and implement
technical training for employee
• Responsible for making “make” vs. “buy” analysis and decision for assemblies.
• Perform Yield and CPK analysis for critical processes.
• Effective in determining root cause and corrective actions on startup production issues.
INNOTEK SUPPORT INC -Project Manager Bloomfield, CT 01/2004-10/2006
• Responsible for developing a project plans and delivery schedules of engineering turn-key
solutions to our customers for R&D, NPI, System Integration, and Manufacturing applications.
• Account manager and main company interface to our customer in multiple facilities.
• Responsible for driving and understanding customer’s requirements.
• Responsible for developing and presenting concepts, and allocating internal resources to ensure
the successful completion if the projects.
• Responsible for identifying process inefficiencies in current manufacturing processes to drive new
business by offering innovative engineering solutions to our customer.
• Design fixtures to improve manufacturability of products and reduce setup time for customer’s
processes.
Lucent Technologies (Bell Labs) - Manufacturing Engineer N. Andover, MA 5/1998-
10/2003
• Worked concurrently with R&D, organizations and vendors through all phases of the product
cycle to ensure a successful on time release of new products. Implemented lean manufacturing
methodologies and processes for new products.
• Planned and coordinated model builds and manufacturing transition of the new products to the
production floor. Provided model evaluation and design for manufacturing input to R&D for
mechanical designs.
• Influenced and ensured that quality processes and cost effective methods of manufacturing were
utilized in the production of products.
• Developed and implemented assembly and quality processes and worked with subcontractors to
assess capabilities, reviewed process plans and controls, drove continuous improvements, and
resolved production issues on the floor.
• Performed source inspection at contract manufactures of products and generated feedback
reports and tracked any action items.
• Created and maintained assembly instructions for the manufacturing of production products and
provided training on procedures and assembly methods for various product lines.
• Worked with supply chain to ensure that material was properly set up in our systems and
available on time.
• Created an outsourcing plan to enable Lucent to increase build capacity, have a more robust
supply chain, and to reduce production costs for various product lines
• Responsible for creating and implementing the outsourcing project plans for TDM Wired
Equipment to be outsourced to contract manufactures to expand production.
• Developed capacity planning tools to enable management run different capacity scenarios and
give our sales and marketing teams more accurate production capabilities, and production
volumes acceptance levels.
• Analyzed internal capacity to help determine what product to outsource and provide suggestions
for capital allocation to upper management on a regular basis.
• Worked closely with Production Managers, Test, Product, Process Engineers to fully understand
current and future plant capacity requirements for each product to determine outsourcing
strategies.
Xerox Corporation - Manufacturing Engineer Webster, NY 06/1996-05/1998
• Quality/Process Engineering Consultant to new manufacturing suppliers. Responsible for auditing
the overall production quality of new vendors, compliance with ISO9002 & 14001, and incoming
qualities from vendors for print cartridges and toner dispensers.
• Analyzed current product’s design in an effort to explore different materials and manufacturing
techniques that help in reducing the overall cost of the product. Designed fixtures to stream line
the cycle time and foolproof current processes.
• Created and maintained assembly instructions for the manufacturing of production products and
provided training on procedures and assembly methods for toner dispensers.
• Responsible for rebalancing and troubleshooting the production lines to adjust for changes in
production volume schedules.
Software:
MS Project, Oracle, Omnify, Agile, Tableau, MS Visio, VB, Microsoft Office Tools, Minitab 16, Sketchup
Education & Professional Development:
Bachelor of Science in Mechanical Engineering – University of Massachusetts (Amherst) – 1996
Advance Problem Solving – Worcester Polytechnic Institute -2010
Advance SPC Training – MKS – 2009
Basic Lean Training – Coherent – 2007
Fluent in Spanish
References:
Available upon request
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