Manufacturing Engineer

BILL M. BARNES

870-***-**** • **************@*****.***

www.linkedin.com/in/billmackbarnes • Pompano Beach, FL

CONTINUOUS IMPROVEMENT MANUFACTURING ENGINEER

Experienced medical device and aerospace manufacturing engineer with hands on production is searching for a

challenging position to develop, implement, maintain, and improve manufacturing processes (including Supplier

Assessment, Assembly/Rework and Process Validation) as well as to optimize quality and productivity to ensure

cost reduction, production flow, rapid problem solving and to reduce customer escapes.

PROFESSIONAL EXPERIENCE

PRODUCTION ENGINEER 2013-2014

Covidien (New Wave Surgical Corp.) – Pompano Beach FL ISO 13485, 21 CFR 820 (QSR), MDD/93/42EEC

Increased production output of Class II FDA medical devices while lowering labor costs. Purchased and installed new

equipment to improve productivity. Designed new tooling for Production. Redesigned existing tooling and equipment to

improve reliability, boost output and increase operator safety. Wrote and performed OQ PQ IQ validation and reports. Put

new pouch sealer into Production that had not worked since new. Established spare parts management for production

equipment. Performed repairs and preventative/predictive maintenance per CMMS. Support QMS and CAPA System per

21 CFR 820. Wrote assembly procedures for products. Conducted root cause investigation of product failures and

customer returns. Worked with offshore suppliers to resolve non-conforming material issues. Optimized final assembly.

Corrected labeling problems. Worked with sterile barriers, final packaging, display boxes and shipping boxes. Wrote EHS

procedures for Lockout Tagout, equipment service and maintenance.

MECHANICAL ENGINEER 2007-2013

Valve Research & Manufacturing Co. – Deerfield Beach FL ISO 9001, ANSI/ISO/ASQ Q9001 and AS9100

Adept at creating Work Orders for bill of materials and assembly procedures in Epicor. Determined the most effective and

efficient ways to use manpower and machines to manufacture a product using Lean and Six Sigma methodologies.

Participated in the design of over 25 new valves. Defined requirements based on Customer Procurement Specifications.

Compiled customer design reviews, FMEA and MTBF. Specified Design and Acceptance Test Procedures. Streamlined

new designs for manufacturing. Established Process Specifications for new equipment and procedures. Designed and

built new tooling for Assembly and Test including hydraulic test stands for hydraulics, fuel and air. Redesigned existing

fixtures to improve repeatability and ease Assembly. Manufacturing processes included conventional machining (CNC

turning, milling, and multiaxis including ID and OD threads) and non-conventional machining (grinding, EDM, and lapping),

surface treatments (electroless nickel, alodining, anodizing, and laser marking), heat treat, vacuum and hydrogen

annealing, and joining processes (welding and brazing). Researched capital equipment and recommended Plasma over

EB, Laser, Resistance, and Capacitor Discharge to replace the current TIG welder. Fluent reading and creating hydraulic

and electrical schematics, blue prints, engineering drawings and working with 3-D CAD models.

Drove continuous improvement in the plant. Trained shop floor personnel on new processes. Initiated Kanban for supplies

and spares; kept maintenance and repair logs. Reduced WIP making on-time-delivery possible to our customers.

• Built a $6,000 dedicated test stand to avoid capital expenditure of $80,000.

• Valve Research grew an average of 25% per year and remained profitable even during the recession.

• Achieved a 22-27% reduction in Assembly and Test labor per year.

• Reduced valve Assembly time by 79% over five years.

• Standardized coil routings and changed coils from a batch job to one piece flow.

• Improved actual valve Test time by 86% per unit.

• Implemented pull system for production through Epicor/Vantage.

• Reduced test queue 80%, improving on time delivery, reducing WIP and freeing up working capital .

• Recommended bringing heat treat in house (two year payback) which would cut process time by 93%.

Processed FAA customer returns. Investigated product quality and process issues. Conduct root cause analysis and

initiate corrective actions. Mapped manufacturing processes to find origins of the defects.

MECHANICAL ENGINEER 2006-2007

Perry Slingsby Systems, Inc. – Jupiter FL BS EN ISO 9001:2008

Designed hydraulic systems and manifolds to decrease manufacturing costs of the next generation of work-class Subsea

Remote Operated Vehicle. Evaluated hydraulic components, created hydraulic schematics, and populated BOM’s in SAP.

Finely honed design and configuration management skills. Designed tooling and test setups.

• Optimized hydraulic systems and eliminated heat buildup while on deck adding value for the customer.

Resume of Bill M. Barnes, Continued

TEST ENGINEER 2005-2006

East West Technology Corp. – Jupiter FL A2LA ISO/IEC Guide 17025, DESC, Boeing, GE, LM, P&W, RR

Performed qualification tests and extended endurance tests of commercial and military aircraft components for a

nationally recognized independent test facility. Designed test setups, supervised production, and monitored tests. Good

project management skills were required to take care of overseas customers, short time frames, and critical results.

• Brought all projects in on time and under budget.

TEST ENGINEER 2003-2005

Texas Hydraulics, Inc. – Temple TX ISO 9001:2008 and ISO 14001:2004

Designed test setup and performed engineering qualification tests and extended endurance testing on custom engineered

hydraulic cylinders. Used data acquisition equipment to verify new cylinder designs and troubleshoot scissor lifts.

Designed tooling for test.

• Initiated use of PLC to run and monitor extended cylinder testing.

TEST ENGINEER 2000-2003

Robert Bosch Tool Company – Walnut Ridge AR / Chicago IL ISO 9001 and ISO 14001

Tested power tools for safety, UL, and IEC compliance testing for the largest power tool manufacturer in the world.

Performed hand and automated testing of hand tools. Performed cord, temperature rise, and motor performance tests.

• Redesigned and modified existing cord test fixtures to shorten test time by 73%.

• Developed test to reject defective cords within 60 seconds saving the company significant time and money.

[Test became known as “Bill Barnes” test.]

TERRITORY MANAGER 1995-2000

MacDon, Inc. - Winnipeg MB Canada / Kansas City MO ISO 9001

Outside sales specialty draper headers for combines to dealers in AR, LA, TX, MS, and MO.

• Quadrupled sales of combine headers to dealers over five-year period in a region covering parts of 5 states.

RESEARCH ASSISTANT 1994-1995

University of Arkansas - Fayetteville AR

Designed, built and tested a sprayer for operation in a flooded rice field.

EDUCATION

Master of Science, Biological and Agricultural Engineering 1994

University of Arkansas, Fayetteville, Arkansas

CGPA 4.00/4.00

Bachelor of Science, Biological and Agricultural Engineering 1991

University of Arkansas, Fayetteville, Arkansas

CGPA 3.40/4.00

PROFESSIONAL

Arkansas Board of Professional Engineers & Land Surveyors - Engineer in Training (EIT) - CN 4629

Trained in Practical Problem Solving (Aero Engine Controls)

Trained in 8D Corrective Actions (Continental)

COMPUTER EXPERIENCE

Epicor/Vantage (ERP), SAP, Solid Edge, AutoCAD 2007, SolidWorks 2005, MS Word, MS Excel, MS PowerPoint, MS

Windows, MS DOS, DasyLab, SAS, QuickBASIC

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