Manager Engineering

PROFESSIONAL PROFILE

Engineering Leader with over 30 years of leadership experience in design and manufacturing of highly engineered mechanical and electro-mechanical products for the industrial, commercial, military, aerospace and consumer markets.

EMPLOYMENT HISTORY

MACK TOOL AND ENGINEERING INC. South Bend, IN

2014 to 2016

A family owned machine shop fabricating parts for the aerospace and medical industries.

Director of Engineering

Engineering leader for the company; assisting the owner in growing the company. Initial project is evaluating and implementing a new ERP system for the company.

Developed and documented the process information for the creation of aluminum, various steels and titanium, high mix / low volume parts including the outside processing required. The aerospace and medical parts were very high precision and required processing and planning for plating thicknesses, heat treatment, etc.

Scheduled Design Reviews and NPI Kick Off meetings for new parts and changes to existing parts. Set up processes and documentation for assemblies of parts; modifying the plant layouts where required based on continuous improvement actions.

Developed PFMEA’s, Control Plans, RCCA’s (Root Cause Corrective Actions), etc. to meet the customers’ requirements.

Worked directly with aerospace customers in the manufacturing, revisions and deviation submittals of their parts and in various continuous improvement initiatives.

HUHTAMAKI PACKAGING INC. (a Finnish company) Hammond, IN

2012 to 2014

A leader in the design and production of disposable packaging; mainly for the food service industries (a ~$2 Billion business).

Engineering Manager

Engineering leader for engineering and maintenance groups for a plant producing molded fiber products. Organizing the maintenance and various capital improvement projects for a high volume 24/7 plant. Implemented a new line producing molded fiber laminated bowls and utilized continuous improvement techniques to increase the output to meet the production output goals.

ALCOA FASTENING SYSTEMS (a division of Alcoa, Inc.) Kingston, NY

2008 to 2012

A leader in the design and production of fasteners and installation tooling for the aerospace and transportation industries (a >$1 Billion business).

Engineering Manager

Engineering leader for a group of 10 engineers and designers responsible for the design and manufacturing support of installation tooling for most of the Alcoa Fastening Systems fastener lines. Managed outside contractors to support FEA analyses, special tool designs and various testing.

Coordinated the technology sharing with a Chinese company to produce similar tooling in China.

Developed the hydraulic and pneudraulic tooling for the fasteners utilized in airplanes, trucks, railcars, etc. This includes several hundred custom noses and special tools, designed in Unigraphics NX6, to meet CE requirements. The Kingston facility machines and assembles parts for the tools, noses and hydraulic rigs sold both domestically and internationally.

ALCOA - HOWMET CASTING (a division of Alcoa, Inc.) La Porte, IN 2004 to 2008

A leader in the production of precision investment castings for the aerospace and defense industry.

Manufacturing Engineering Manager / ABS Leader / Manufacturing Manager

Manufacturing Manager of the post-cast, heat treat and finishing areas.

Lean Manufacturing leader for the plant in which I worked closely with Manufacturing to ensure the Alcoa Business System (Toyota Production System) rules were supported. Assisted with the development of standard work, optimized processes and tools, minimized capacity constraints, conducted Kaizens, 5S, eliminated waste, conducted training, implemented four step cells, etc.

Directed the team in charge of identifying, obtaining funding, planning, implementing and validating automation projects for the La Porte Castings plant. Projects included: robotic dispensing, combining a CMM with a 5 axis CNC to finish metal parts, introducing digital radiography into the x-ray department, etc. These capital projects had estimated cost reductions of $900,000 annually.

Coordinated various projects with other Howmet facilities.

DWYER INSTRUMENTS, INC., Michigan City, IN

1998 to 2003

A leader in the design and manufacture of measurement and control instruments for pressure, temperature, level and flow applications with annual worldwide sales in excess of $70 Million.

Director of Engineering

•Directed multiple teams and engineering departments in Michigan City, IN and Buffalo Grove, IL with eight direct reports and up to 25 indirect reports in the design, research, development, validation and production support of instruments and controls. Additionally responsible for the Corporate Quality Assurance function. Budget responsibility for New Product Research & Development, Product Enhancement & Support, Quality, and Manufacturing Engineering with a total annual budget of $5.8M. Participated in the strategic planning for the company.

•Developed and released 22 new products in 2002 (19 in 2001, 22 in 2000 & 21 in 1999) while supporting a line of 5,000 products and generating cost reductions of $350,000 to existing products. Major new product lines developed: new pressure transmitters, pump controllers, dust control timers, dual zone temperature controllers, Polysulfone flow meters, flow transmitters, hand held products (for pressure, temperature, CO monitoring), digital pressure gages, air velocity transmitters and pressure / flow switches.

•Developed several product line options including Modbus communications and various agency listing approvals (UL, CE, CSA, FM, ATEX).

•Created 300 to 400 customer specific products each year generating several million dollars in annual sales.

•Implemented financial analysis process to select new product development proposals with the highest potential sales, acceptable payback periods and highest margins while making the best use of the mix of engineering expertise and capital tooling investment.

•Initiated radical cultural changes that reduced product development cycle times through process enhancements, reuse of existing software designs, improved planning, teaming with Sales & Manufacturing and continuous improvement. Two major new products were each developed in under 2 months.

•Organized the implementation of a quality auditing system for the manufacturing plants and created an increased focus on quality. Warranty returns decreased by 59% in 2002.

•Responsible for legal support of patents, trademarks and product liability issues.

•Directed the modernization of the engineering computer systems / networks and software (implemented email, tied networks together, instigated electronic print access at remote plants, switched from Pro/E to SolidWorks).

ALLEN-BRADLEY (Rockwell Automation), Milwaukee, WI

1989 to 1998

Allen-Bradley, a business unit of Rockwell Automation, is a leading industrial automation company providing power, control and information products. Rockwell Automation had annual sales in excess of $4 Billion.

Program Engineering Manager

1993 to 1998

•Supervised and directed multiple teams and engineering departments with up to 16 direct reports in the research, development and validation of new industrial control products and production support of existing products with a budget responsibility in excess of $3M.

•Facilitated the SMP/MCS-E program, a $40M project to develop a line of electronic overload relays, which included 82 plastic mold dies, 101 stamping dies, firmware development and testing/validation to domestic and European standards (UL, CSA, CE, IEC, etc.). Teamed with sister company in Switzerland on new product development.

•Functioned as project engineering leader for the SMC Dialog Plus (softstarter market leader) product line development involving a new communications protocol, 2 new microprocessors, a new power supply and the implementation of newly patented algorithms (in collaboration with Sussex University in England). Championed the implementation of a new product development system involving several new software packages and cultural changes.

•Collaborated with Marketing in the definition and evolution of the softstarter and overload product lines.

Senior Project Engineering Supervisor

1989 to 1993

•Managed 15 mechanical engineers, electrical engineers, designers and printed circuit board designers with product design and production support responsibilities.

•Assigned technical resources to new product development teams involved with smart motor controllers, timers, solid state overload relays, and starting torque controllers.

•Functioned as an ISO 9001 Internal Systems Assessor / Instructor. Training included an in depth internal pilot audit for over 80 personnel resulting in complete certification of all departments involved.

•Managed the CAD environment for the printed circuit board design (Mentor Graphics) and mechanical design (Pro-Engineer).

MAGNAVOX GOVERNMENT & INDUSTRIAL ELECTRONICS CO., Ft. Wayne, IN

1986 to 1989

A government contractor developing and producing state of the art military electronics. Magnavox is the leading supplier of sonobuoys for the Navy.

Project Engineer / Senior Mechanical Engineer (1986)

1986 to 1989

•Managed six electrical and mechanical engineers and technicians with design, validation, production support and cost reduction functions. Security clearance: Secret.

•Provided technical responsibility and production support for the AN/SSQ-53B sonobuoy line with U.S. Navy contracts up to $90M in one year (300,000 units).

•Enhanced production and design to obtain quality levels to allow for ‘skip lots’ saving the company approximately $400,000 resulting in higher than planned profits.

•Interfaced directly with the customer in negotiating changes to the Navy contracts, specification changes, waivers, deviations, and testing. Prepared and presented ‘bids and proposals’ with manpower, material, and travel estimates.

•Designed sonobuoy parts and interfaced with vendors on cost reductions and tooling (plastic molds, steel rule dies, progressive dies, impact extrusions, salt water batteries, etc.).

MOTOROLA COMMUNICATIONS, INC., Ft. Lauderdale, FL

1979 to 1983; 1984 to 1986

A global, electronics and communications company. The Ft. Lauderdale division produced two-way portable products.

Senior Mechanical Engineer

•Developed new two-way portable radios with their batteries and accessories.

•Provided finite element analysis utilizing SAP6, ELAS and ANSYS.

•Mechanical packaging and interconnection design of hybrid modules (thick film and thin film) and multi-layer printed circuit board design. Performed shock, vibration, heat transfer and tolerance analyses.

•Received Engineering Award for the development of an automated infrared soldering process.

RCA CONSUMER ELECTRONICS, Indianapolis, IN

1983 to 1984

A global supplier of televisions and high technology products.

Mechanical Engineer

•Provided mechanical design and analysis for television design in addition to production support.

EDUCATION / QUALIFICATIONS

MBA, Marquette University, Milwaukee, WI (1993)

BSME, Rose-Hulman Institute of Technology, Terre Haute, IN (1979)

PE, Professional Engineer (registered in Indiana)

Training: Six Sigma Green Belt, ISO 9001 Facilitator, Lean Manufacturing, Pro-Engineer, Mentor Graphics, Kepner Tregoe Project Management, Microsoft Project, AutoPLAN II Scheduling Software, Microsoft Office Suite, DFMA, SAS Programming, Unigraphics NX6

PATENTS

Controller Module Package Design, Patent # 4,490,813

Remote Microphone Design, Patent # 4,679,233

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