Metals Manufacturing Expert - Supplier Quality Engineer - Inspector

David “Mac” McCracken, CMI, CQI

**** ******* ******, ***** *-726, Houston, TX 77098 E-mail: **********@*****.*** Cell Phone: 412-***-****

LinkedIn Profile: http://www.linkedin.com/in/davidmacmccracken

Metals Manufacturing Expert – Supplier Quality Engineer – Source Inspector

“Hands-on” experienced Manufacturing Engineer, Metallurgist, and Supplier Quality Engineer, specializing in metals manufacturing, industrial equipment manufacturing, supplier quality assurance, and source inspection for major clients including Alstom, Apple, Borg Warner, BP, ExxonMobil, GE, Mitsubishi, Rolls-Royce, Shell, and Solar Turbines.

Consulting Experience

MANUFACTURING ASSURANCE CONSULTANTS, INC. (MAC) www.SupplierQA.com (2010-Present)

Founder – Metals Manufacturing Technical Services – Principal Metals Manufacturing Engineer – Expert Witness

Provide technical program management guidance and market-based consultations to private equity firms and start-ups.

• Perform market research and analysis of existing and emerging markets for metals products and engineered equipment.

• Develop market-based business development strategies and perform due diligence projects for major corporate clients.

• Provide start-up, transitional, and interim manufacturing management leadership and support services to start-ups.

• Expert Witness in court cases involving market-based claims, manufacturing defects, patents, and shipping damage.

• Clients: Alphasights, Bain & Company, Boston Consulting Group, Gerson Lehrman Group, McKinsey & Company.

INTERNATIONAL SUPPLIER QUALITY CONSULTANTS, INC. (ISQC) www.SupplierQA.com (1997-Present)

Founder – Supply Chain & Supplier Development Services – Principal Supplier Quality Engineer – Expert Witness

Contract supply chain management, supplier development, and supplier quality management services. (100% travel)

• Perform supplier quality surveys and audits, vendor surveillance, source inspections, and manufacturing expediting.

• Develop casting, forging, stamping, metal forming, and manufacturing production processes at suppliers worldwide.

• Consulting Expert and Expert Witness in court cases involving supplier quality, product liability, and personal injuries.

• Clients: Alstom, Amtrak, Apple, Aramco, BP, Chevron, ExxonMobil, GE, Johnson & Johnson, Rolls-Royce, and Shell.

Operations Management Experience (Salaried Employee)

ZEP SOLAR (Solar Panel Mounting Hardware OEM Start-Up) San Rafael, CA (2010)

Director of Manufacturing - Solar Hardware Design for Manufacturability - Sourcing - Procurement

• Design for Manufacturability (DFM) / Design for Six Sigma (DFSS) of solar panel mounting hardware components.

• Sourced, surveyed, contracted, and managed contract manufacturing suppliers of solar panel mounting hardware parts.

HOLTEC MANUFACTURING (Nuclear Power Generation Equipment OEM) Pittsburgh, PA (2008-2009)

Contract Manufacturing Supply Chain Manager - Sourcing - Procurement - Supplier Development

• Project Manager for $5M Westinghouse Nuclear modified reactor head vessel weld fabrication project.

• Managed estimating, sourcing, and materials procurement per ANSI N45.2, NQA-1, & 10CFR50 Appendix B.

• Sourced, surveyed, contracted, and managed welding fabricators for spent fuel rod containment vessels.

INFINIA CORPORATION (Solar Concentrator Stirling Engine OEM Start-Up) Kennewick, WA (2008)

Global Supply Chain Manager - Sourcing - Procurement - Solar Engine Supplier Development

• Design for Six Sigma (DFSS) and Design for Manufacturability (DFM) for Stirling engine components.

• Sourced, surveyed, contracted, and managed Solar Engine part manufacturing suppliers for NPI launch.

APPLE (Tooling & Equipment - Strategic Materials - Mechanical Enclosures) Cupertino, CA (2007)

Sr. Supplier Quality Engineer/Manager - Strategic Metals Technical Liaison - Supplier Development

• Managed Apple SQEs at Foxconn and other suppliers requiring 80% travel to China, Japan, and Taiwan.

• Lead SQE for aluminum extrusions, stampings, plastic, and glass enclosures for the new iMac computer.

• Metals process development technical liaison to Alcoa Aluminum and Ulbrich Stainless & Titanium.

TRINITY RAIL – McCONWAY TORLEY (Steel Castings Foundry) Pittsburgh, PA (2003-2004)

Melt Shop Manager - Casting Supervisor - QA/QC Inspector - Level II MT, PT, UT NDT Inspector

• Hired as transitional management to replace foundry Melt Shop Manager and Casting Floor Supervisor.

• Managed melt shop operations personnel, supervised EAF melting, chem. lab, and casting operations.

PITTSBURGH FLATROLL COMPANY (Aerospace & Nuclear Metals) Pittsburgh, PA (1996-1997)

Quality Manager - Principal Process and Product Metallurgist - High Temperature Superalloys

• High temperature jet aircraft engine materials for General Electric, Pratt & Whitney, and Rolls Royce.

• Managed titanium, high temperature alloy, and exotic superalloy plate and sheet rolling mill operations.

Selected Supplier Quality Management Projects

SOLAR TURBINES – CATERPILLAR CORPORATION (Gas Turbines) San Diego, CA (2006)

Sr. Supplier Quality Engineer - Castings & Forgings Subject Matter Expert - Technical Advisor

• Castings & forgings Subject Matter Expert consultant to Global Supplier Development Group.

• Turbine manufacturing and assembly technical advisor for casting and forging supplier issues.

• Performed Material Review Board (MRB) investigations and drove supplier corrective actions.

BORG WARNER TURBO SYSTEMS (Automotive Turbochargers) Asheville, NC (2005-2006)

Sr. Supplier Development Engineer - Investment Castings - Metal Injection Molded (MIM) parts

• High temperature turbocharger component product development for Ford Motor turbochargers.

• Solved metallurgical problems by developing novel investment casting techniques and processes.

• Performed “hands-on” precision dimensional inspection for run-off and run at rate qualifications.

• Developed melting, casting, machining, grinding, and heat treating practices that improved Cpk.

• ISO/TS16949, APQP, PPAP, FMEA, DOE, 8D Problem Solving, 5-Whys Root Cause Analysis.

FLORIDA POWER & LIGHT (Nuclear Utility) Port St. Lucie, FL - Seabrook, NH (2005-2006)

Supplier Surveillance - Resident QA/QC Source Inspector - Technical Advisor - Expeditor

• Technical supplier management of GE Nuclear Custom Fab welding and machining operations.

• Surveillance of NQA-1 QA/QC & ASME Section III weld fab, machining, assembly, and NDT.

GENERAL ELECTRIC (Diesel-Electric Locomotive Engines & Turbochargers) Grove City, PA (2005)

Sr. Supplier Development Engineer - Castings & Forgings - Assembly Line Technical Advisor

• New Component Introductions and Lean 6 Sigma NPI manufacturing launch of GEVO engine.

• Developed global supply chain casting and forging suppliers in Brazil, Germany, India, and the US.

• Large ductile iron engine block castings, forged crankshafts, and high-temp alloy turbochargers.

• Rapidly solved a major crankshaft failure problem by investigating supplier forging practices.

NORTHROP GRUMMAN (Electro-Mechanical Enclosures) Baltimore, MD (2004-2005)

Sr. Supplier Quality Engineer - Supplier Surveillance - Resident QA/QC Source Inspector

• Developed sole supplier’s metal stamping, forming, welding, painting, and assembly processes.

• Performed vendor surveillance, First Article Inspections (FAI), and supplier source inspections.

TECO ENERGY – TAMPA ELECTRIC COMPANY (Electric Power Utility) Tampa, FL (2002)

Supplier Surveillance - Resident QA/QC Source Inspector - Technical Advisor - Expeditor

• Monitored steel roll forming and welding operations at Thermal Transfer Corp., Duquesne, PA.

• Inspected electrostatic precipitator welded steel panel assemblies and electrode discharge tubes.

DANIELI CORPORATION – NIPPON STEEL (Steel Mill Equipment) Buttrio, Italy (1999-2000)

Customer-Supplier Liaison - Equipment Installation - USIMINAS, Minas Gerais, Brazil

• Technical Liaison for Italian and Japanese OEM clients for installation of $100M equipment line.

• Identified actual causes for delays and successfully refuted multi-$M liquidated damages claims.

SHELL DEEPWATER (Offshore Drilling Tension Leg Platforms) Houston, TX (1997-1999)

Customer-Supplier Liaison - Forging & Machining Consultant - Source Inspector - Expeditor

• Shell liaison between FMC Technologies, Wyman Gordon Forgings, and machining suppliers.

• Shell authorized inspector for Shell/BP-Amoco/Conoco-Phillips/ExxonMobil URSA Project.

• Ultra-precision inspection of 40ft long CNC machined steel and titanium TLP tension risers.

MITSUBISHI HEAVY INDUSTRIES (Metals Machinery Division) Hiroshima, Japan (1997-1998)

Customer-Supplier Liaison - Metals Manufacturing Technical Advisor - Project Expeditor

• Expedited welding, machining, and equipment suppliers for $200M continuous galvanizing line.

• Managed heavy structural steel welding fabricators, roll manufacturers, and machinery builders.

Education and Certifications

University of Pittsburgh, The Ohio State University, Capital University – Metallurgy, Physics, Math

American Society for Non-Destructive Testing – Certified Level II MT, PT, RT, UT, VT NDT Inspector

American Society for Quality – Certified Mechanical Inspector (CMI) / Certified Quality Inspector (CQI)

American Welding Society – Welding Inspection

Contact this candidate