Engineer Manager
Resume:
Michael C. Pilla
Orlando, FL *****
acf9rv@r.postjobfree.com LinkedIn:www.linkedin.com/profile/view?id=151088343
DoD Security Clearance: Secret
Professional Summary:
Supplier Quality Engineering Manager, who applies design engineering, manufacturing engineering, quality engineering, ISO 9001 and AS 9100 expertise to prevent issues from occurring as well as resolve issues which arise to maximize customer satisfaction.
Professional Experience:
Raytheon Co., Andover, MA; Supplier Quality Manager, 2002 to 2014;
Solved and resolved quality, manufacturing and design engineering issues at key suppliers to Raytheon which assured supply chain and operations were provided with on-time quality components to support customer requirements. Used entire skill set of technical and quality techniques to perform failure analyses and process audits which brought forward solutions to chronic issues with waveguides, microwave assemblies, missile gyro’s, printed wiring boards, electrical cables, castings, welded products and complex machined parts.
Accomplishments at Raytheon;
Challenge: Missile Gyro Intermittent Failures
Action: Six Sigma based failure review to identify root cause
Result: Failure mode identified insufficient hydraulic fluid filter size. Filter size reduced to below minimum design clearance and the issue was eliminated.
Impact: 30% increase in first pass yield at missile guidance section acceptance testing
Challenge: Waveguide test failure after installation to next higher assembly
Action: Process mapped waveguide fabrication and assembly steps
Result: Failure mode identified as assembly tooling weakness which allowed the waveguide to be micro-cracked at installation. Tooling revised to eliminate waveguide installation damage.
Impact: No further issues over next 8 years of continuous production
Challenge: Missile waveguide filter VSWR failure at next higher assembly installation.
Action: FEMA review from design requirements to acceptance testing VSWR.
Result: VSWR test sampling granularity stated as a range. Waveguide supplier sampled at the low end of range and next higher assembly tested at the high end sampling, allowing VSWR cycle out of tolerance test points to escape identification.
Testing requirements aligned with engineering change and acceptance testing alignment.
Impact: 20% increase in first pass yield at next higher assembly test.
Challenge: Printed wiring board pad lifting at printed wiring assembly.
Action: Process mapping at board fabricator supplier.
Result: Failure mode identified as inspection omission escape prior to board dicing. Fabricated boards inspected / X out defects identified before dicing and sample inspection of diced boards.
Impact: No further defectives in over 400 boards per radar through 7 more radar deliveries.
Michael C. Pilla
Beacon Power Corp, Tyngsboro, MA; Manufacturing Manager, 2000 to 2002;
Provided entire skill set of engineering and manufacturing skills to this start up company. Successes included entire plant layout at new facility, machining center equipment procurement, installation and prove out, material handling, product packaging, process development, test planning and supplier issue resolutions.
Textron Defense Systems, Wilmington, MA, Supplier Quality Manager, 1994 to 2000;
Evaluated and resolved various design, manufacturing, quality issues with the supplier base. Also, interfaced with government customer and had sole responsibility for the final approval of packaging designs and shipments of HAZMAT materials (weapon grade high explosives in assemblies) from company locations to customer field centers.
Accomplishments at Textron;
Challenge: Machining issue holding wall tolerance of machined casting at suppliers
Action: Worked with design engineer to identify available dimensional clearance at next higher assembly. Coordinated an engineering design change and manufacturing process change to add milled flats on the outer wall diameter of this machined cartridge instead of lathe turning the OD.
Result: No further scrapped castings post machining due to insufficient wall thickness.
Impact: Deployment performance accuracy of the cluster weapon cartridge increased significantly and customer highly commended the change to company management team.
Challenge: Inconsistent fabrication and inspection practices on the designs of a new product in design development due to lack of key characteristic designation on the design drawings.
Action: Lead daily two hour working group for three months with design engineer and manufacturing engineer to add the appropriate key characteristics and improve ANSI Y14.5 geometric tolerance designations to accommodate implementation of functional gages as much as possible.
Result: Eliminated any questions from supplier base on key design features and inspection set up method. SPC was applied to critical design features for measurements / inspection data via in-line probes. Many functional gages were also added for quick and effective discrete measurements where they could be applied.
Impact: Significant reductions in process and inspection cycle times. Lower costs to suppliers, company and customer resulted in an add on contract in to the program out years.
Education:
MS Engineering Management; Northeastern University, Boston, MA
BS Industrial Engineering; University of Rhode Island, Kingston, RI
Profession Certifications:
Certified ASQ Quality Engineer (certificate # 45672)
Certified ISO 9001 assessor (certified by Kennedy and Donkin)
Certified HAZMAT packaging engineer (from Aberdeen Proving Grounds)
Certified ANSI Y14.5 GD&T expert
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