Engineer Project Manager
Resume:
JAMES H. SAGER
Milwaukee, WI 53217
Phone 414-***-**** E-mail ***********@*****.***
Job Objective: Senior Engineer or Manager of, Manufacturing Engineering, Quality, or Test.
Managerial and technical experience in military, industrial and, automotive businesses in both union and non-union environments. Extensive background in team building, continuous improvement, and cost reduction utilized in leadership of, Manufacturing and Quality Engineering functions for a manufacturer of eledtrical equipment.
2008 to Present Eaton’s Cooper Power Systems . Waukesha Wi. – Lead Manufacturing Engineer
Responsible for manufacturing and test processes used in the manufacturing of power transformers ranging in size from 1 to 16 MVA. Analyzed in-process failures and determined root cause and corrective actions necessary to improve the vacuum drying process. Revised visual operating procedures and trained operators.
Net Results: Cost savings ideas implemented saved $400,000 per year and improved capacity 20 %.
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Performed root cause analysis on Power Factor failures of our transformers. Determined the cause to be the quality of our purchased core steel. Designed unique test equipment that could detect defective edge burrs and/or surface coatings. Developed unique test methods that could quickly detect failures in rolls of steel at receiving or completed transformer cores. Developed simple repair methods to repair transformers during assembly.
Net Results: Eliminated failures that previously could not be found until final test and required total rebuild of the transformer. Cost savings $540,000 per year.
Also our US steel manufacturer now uses my test equipment to test his steel in process because it works better than the industry standard test method.
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Lead a team to investigate the possibility of using un-annealed core steel as a method to eliminate the annealing process thereby reducing process time, labor and electric power.
Net Results: Cost savings of about 180,000 per year.
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Lead a team power testing specialist’s to determine the reliability of our 30 year old power testing system. The conclusion was that the system had a 98.8% chance of failure in the next 5 year period, which could stop shipments of most of our products for 6 to 12 months.
Net Results: I have lead a team to define the future testing needs, wrote the specifications for test equipment and negotiated the purchase contracts for a multi-million dollar power testing system.
2006 to 2008
Pentair Water Treatment, Brookfield /Sheboygan WI.– Sr. Project Engineer-Design & Reliability
Responsible for obtaining UL, CSA, CE, and CEC, certifications of control systems. This includes negotiations with agency engineers and supervisors and the redesign of products to meet agency and APQP & PPAP requirements while meeting product launch schedules.
Net Results: Cost savings idea while implementing CEC saved $100,000 per year…
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Supported the Operations Department with assembly training and product failure analysis. Net Results: Isolated and eliminated firmware defects. Reduced customer complaints 50%.
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Implemented HALT on two major products, then analyzed life test and field data.
Net Results: Implemented design improvements which increased MTBF ten fold…
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Designed high reliability redundant electronic control systems for commercial, industrial and military water treatment systems.
Net Results: My high reliability automated drinking water testing and sterilization control system will be used on the USS Freedom and all future Littoral Combat Ships.
2005 to 2006 Part Time
Consultant
Kohler Corporation, Kohler Wisconsin – Consultant, Automated assembly equipment design
Designed and built the first production unit of a mobile assembly station for 990 CC engines. The specification required that the articulation system must be able to raise, lower, and rotate a 100 pound engine to 11 programmable positions, as the engine travels between assembly stations. The control system was required to be explosion proof with a self contained power system capable of operating 300 positioning cycles during a 10 hour shift with out need for recharging.
Net Results: My design reduced the cost of each assembly cart by $3000 saving about $72,000. The unique design is patented.
2002 to 2006
Earlier Positions
Held
The Brewer Company, Menomonee falls, Wisconsin – Sr. Electrical Eng / Project Manager
Designed and tested actuator and control systems for powered moveable medical exam tables. Life tested all subsystems, both electronic and mechanical, and the complete medical exam table for the equivalent of 15 years of use. Used HASS and HALT Highly Accelerated Stress Screening, and Highly Accelerated Life Testing to produce an extremely robust design.
Net Results: One of our suppliers was so impressed with how I tested and certified their actuators that they purchased the life test system, which I designed and built, to use at their factory to test the product improvements, which I suggested.
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Implemented multiple safety features to prevent patient injuries…
Net Results: The exam table was chosen as the best example of safety design at the show.
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Designed and built a PLC automated display system for the sales booth used to introduce the exam table. Net Results: Sales booth received first place award at the show.
AO Smith Research Center, Menomonee falls, Wisconsin - Consultant - UL, FMEA, & Mfg. Eng.
Consultant responsible for rapid implementation of UL 1998 Certification of a microprocessor programmable control system. Conducted FMEA & FMET Failure Modes and Effects Test and verified safe shut down of the 5,000,000 BTU boiler systems, after introducing a hard failure, for each and every electronic component in the control system. Set up the pilot runs and production builds for the control system, including supplier quality audits, supplier selection, and testing requirements and test equipment selection.
Net Results: After AO Smith had 2 years of minimal progress with UL, I was able to complete the safety test and obtain UL certification in 6 months while simultaneously setting up test and production process at the expected cost for testing and tooling.
Plexus - Electronic Assembly Corp, Neenah, Wisconsin
Sr. Quality /Manufacturing Engineer
Eaton Corporation, Cutler Hammer Products, Milwaukee, Wisconsin
A manufacturer of industrial and military controls.
Supervisor of Design
Principal Process Development Engineer:
Magnetek Inc., New Berlin, Wisconsin
Project Manager/Manufacturing Engineer
Supervised 20 direct reports
Johnson Controls, Milwaukee, Wisconsin
A manufacturer of HVAC equipment.
Project Manager/Senior Design Engineer
Supervised 5 to 10 direct reports
Senior Design Assurance Engineer
Electrotek Corporation, Milwaukee, Wisconsin
A manufacturer of printed circuit boards,
Vice President of Manufacturing Engineering and Quality Assurance
Supervised 20 direct reports, 1 supervisor, 4 engineers and 15 technicians.
General Electric Medical Systems. Milwaukee, Wisconsin
A manufacturer of medical imaging equipment.
AQCE (Quality Project Manager)
Eaton Corporation - Cutler Hammer Products, Milwaukee, Wisconsin
A manufacturer of industrial and military controls.
Test Supervisor/Test Engineer
Supervised 17 Test Technicians.
Education:
BSEE Marquette University, Milwaukee, Wisconsin
ASEE Milwaukee Area Technical College, Milwaukee, Wisconsin
Professional
Training:
Project Management Basics - IIL
Supervision of CAD Design and Drafting - UWM
Electro-Magnetic Compatibility Design and Test - UWM/DLS Engineering
Continuous Flow Manufacturing - UWM
Front Line Leadership - Zenger Miller
SPC Methods for Short Run Operation - Milwaukee School of Engineering
Simultaneous Engineering Methods - University of Wisconsin Milwaukee
Taguchi Methods for Design of Experiments - Milwaukee School of Engineering
Management Problems Analysis (12 month MBA program) - GE Medical Systems
Certifications:
ASQ Certified Quality Engineer, Green Belt
Patents:
Coil Retainer/Positioner - Patent 96-L06-367
Software Skills
Windows, Word, Excel, Access, Lotus Notes, MS Schedule, MS Project, Power Point,
Photo Editor, Mini Tab, AMAPS, Manage PRO, SPC PRO, PLC Ladder Logic
REFERENCES
Don Anderson John Bruwer
Maintenance/Shipping Supervisor Six Sigma Master Black Belt
Eaton’s Cooper Power Systems Eaton’s Cooper Power Systems
Work phone 262-***-**** Work phone 262-***-****
Email ****************@*****.***
William Koller Ken Miller
Manufacturing Services Manager Project Engineer
Eaton’s Cooper Power Systems Pentair Water
Work phone 262-***-**** Cell Phone 920-***-****
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