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Mechanical Design Engineer, Engineering Manager, FEA, DFM, FMEA, CAD

Minneapolis, Minnesota, United States
January 18, 2017

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Experience Summary

Over ** years of product development and technology management. Proven ability to identify customer’s needs and create products to satisfy them. Recognized as a catalyst for the adoption of new technology and cross departmental team building. Introducing new technologies such as 3D printing and 3D scanning as organizational systems to ensure the corporate culture adapts to their use efficiently.

Management Skills Summary

Extensive experience with R&D project and team leadership through all phases of the development cycle. Formerly manager of engineering technology systems, with oversight of CAD service group, Change Management Systems, and Technical Publications. Advisor for the development of a rapid prototyping department.

Technical Skills Summary

Mechanical designer engineer, inventor on 4 patents. Skilled at design analysis: FEA, bearing life, DFM, FMEA, etc. Skilled observer of human interactions with machines and software (Human Factors). Able to translate observations/customer-needs into product ideas and technical specifications. Expert at the use of CAD for product design and visualization. 10 years of experience with SolidWorks and several years of use with Rhino, MODO, ZBrush, and Photoshop. Expert in the use and selection of rapid prototyping processes including 3D printing, 3D scanning, and silicone/urethane (RTV) molding. Design coach for R&D in fabricated parts and the use of GD&T.

Public Presentations

Round Table Discussion Facilitator, on 3D Printing, at the Professional Retail Store Maintenance Association, April 2014. Interviewed on KSTP News for manufacturing week, October 2013. Speaker at the Additive Manufacturing User Group AMUG, April 2013. Speaker at multiple presentations to the Minnesota SolidWorks Technical Forums, 2012, 2013.

Web Presence

Linked-In, Work Experience

2002-Oct 2016 Tennant, New Product Launch. Golden Valley, MN

Principle Fabrication Launch Engineer (2014 – Oct 2016)

Technical liaison for R&D and Fabrication. Primary mission is bringing Designers and Fabricators together to optimize designs for manufacturability and cost reduction, and to improve the product launch process.

Design Coach focusing on design for manufacturability, DFM, for all NPD projects. Currently assisting 4 NPD programs. In the past 24 months we have documented over 1600 DFM suggestions that have a documented cost avoidance of greater than $3,000,000. Suggestions range from geometry changes, material selection, tolerance issues, and mfg process selection. These coaching sessions occurred as 1-on-1 meetings with design engineers and in meetings and with groups of design engineers and fabrication experts.

Launch Process Improvement Efforts:

Standardization and modernization of Quality Control equipment. Identified need for all global QC labs to have the same inspection equipment. Researched QC FAI process and equipment. Got global labs to agree on one set of 3D scanning / touch probe equipment (FARO), which allowed them to share processes with each other and eliminate differences in inspection routines. Wrote Capital Expense Request for $400K of equipment and training for four labs, approved for purchase in Q1 2016. ROI is within 2 years.

Co-Project lead with two other Principle R&D engineers bringing in-house GD&T training to manufacturing and R&D engineers, standardizing common tolerances, and documenting standard drafting callouts. Effort is global and cross functional. Goal is to create a sustainable culture change resulting in non-ambiguous drawings.

Led effort to standardize Fabrication’s process of creating cost estimates. Developed a costing process that matched the phase gate pace of NPD.

Developed a process for executing Plan for Every Part, PFEP. By looking at the total life of a part from raw steel to part shipment, improving ideal lot sizes estimates.

Design lead for modular tilting work stands. Analytically demonstrated the ergonomic benefits of tilting large weld fixtures to improve operator’s reach and reduce back strain. Led a design group to complete the design and manufacture of tilting work fixtures bases, resulting in improved operator safety and productivity, that is being applied to all of the large weld fixtures in the factory.

Tennant, New Product Development. Golden Valley, MN

Engineering Manager, Engineering Services (2012 - 2014)

Manager of Engineering Records/PLM, Variant Configuration, Technical Publications, CAD, and Rapid Prototyping groups. 7 reports, 12 staff.

Responsible for annual operating planning, vender relations, program and staff management, and continuous improvement efforts.

Global business process owner of PLM (product lifecycle management). PLM user group consists of 168 users, spanning 21 cross functional departments, globally.

Consulting member on the user interface development team. Working with industrial design and consumer focus group to optimize the function map on the interface of the “Pro Touch” control panel.

Subject matter expert ensuring that business processes developed match R&D and Operation’s workflow.

Principal Engineer, Engineering Services (2010 - 2012)

Managed the migration from Unigraphics-NX to SolidWorks. Resulted $300K annual savings/year in user training and reduced maintenance costs.

Managed the integration of new PDM software with SAP. Resulted in a measurable productivity increase of greater than $125K per year. This system has become the world standard SAP/SolidWorks integration tool.

CAD skills development lead. Ensuring that the transition from NX to SW resulted in a highly skilled CAD workforce. To date 25% of users have certified SolidWorks certificates (associates to experts), which exceed the national average.

Developer of Rapid Prototype Center: Purchased Stratasys Fortus 400mc, 3D Printer which reduced cost and project time through advanced prototyping techniques. Resulted in a saving of greater than $900/day in prototyping expense. Using it for prototype tooling is offsetting 1300 hours of skilled labor/year. Creating a culture for prototyping that is reducing development time and improving design quality.

Identified and deployed new CAM system, Tebis, resulting in a 70% reduction in programing time for the tooling department.

Developed and demonstrated method for prototyping large rotomolds using painted (to seal) engineering foam and RTV urethane.

Program Manager, Ec-H2O cleaning system installation (2008 – 2010)

Managed global cross functional team to develop and release electrically activated water cleaning system on five different machine platforms.

Responsible for program schedule and budget.

Implemented risk mitigation strategies for development of a new power converter project and matching software development program.

Efforts resulted in five successfully launched new product introductions, all meeting or exceeding QTC goals.

Senior Lead Engineer, Large Rider Sweeper/Scrubber projects (2004 – 2008)

Technical and cross functional lead, responsible for the delivery of two internal combustion powered, hydrostatically driven, cleaning machines. Projects were the second and third machines in a family of platform machines. Resulting in a family of machines that have 70% parts commonality with first machine. Projects were sequential.

Led each team of six mechanical engineers and designers.

Represented the design teams at all cross functional team meetings, kept other departments informed of our progress and challenges. Established and maintained project schedule.

Develop and ensured that all systems meet stated Design Requirements and Objectives (DRO). Methods used include CAD design reviews, initiation of FEA on high load components, UL, CE and internal safety reviews, risk analysis using specification scorecards and FMEA, risk mitigation plans, prototype builds, testing reviews, manufacturing line build, and first article inspections.

ISO Process Manager for five years. Developed and managed NPD ISO process. Participated in audits and corrected any findings.

Designed patented (US 8,584,294) swing-out disk head. Contributed to the design of patented (US 7,805,802) debris tray. New concepts were customer convenience features gleaned from site visits.

Conducted patent research looking for prior art.

Wrote patent disclosures for team.

Conducted ethnographic customer research, globally, to identify best areas of product improvement.

Project Engineer, T7 Small Rider Scrubber (2002 -2004)

Project Engineer responsible for delivery of foot pedal controls, sheet metal frame and various plastic parts. The T7 is battery powered, micro sized, rider/scrubber cleaning machine.

Designed patented (US 7,244,000) Drive-By-Wire accelerator and brake foot pedal assembly. Design improved customer satisfaction and was a significant cost savings over former mechanical assembly. To date over 90,000 units have been made, and are used on 8 different machine lines.

Improved operator ergonomics to remove stress points from operation.

Conducted patent research for prior art.

Other designs include: optimal sheet metal frame, injection molded and powder metal components.

Conducted ethnographic customer research, globally, to identify best areas of product improvement.

1998-2002 Timesavers, New Product Development. Crystal, MN

Lead Design Engineer

Designer of patented Self Centering, Opposed Knife Planer (US 6,470,932). Technical responsibilities included: systems layout, design objectives, CAD design, materials selection, prototype development and testing, supervision of 3 designers, supervise and run prototype testing in off site factory, presentation of design at the International Wood Workers Convention, and installation and training for 3 machines in Canada and USA.

Design Engineer, Low Cost Wide Belt Orbital Sander.

Design Engineer, Low Cost Wide Belt Sander.

Reduced cost and improved reliability through designs using DFMA processes, lowering tolerance requirements, and combining part functions.

1997-1998 Sheldalh Inc, Northfield MN

Process Engineer

Integrated machine vision to web handling equipment.

Maintained a web processing line.

Supervised line crew.

1996-1997 Display Technologies Inc, Hopkins MN

Design Engineer

Designed components for use in ultra-high vacuum manufacturing equipment.

1994-1996 MedAmicus, Inc, Plymouth, MN

Intern Mechanical Engineer

Validation of new product design of a molded catheter.

Design of insert mold tooling.

1983-1995 Various companies, USA

Skilled Tradesman

Trades practiced include: certified welder, sheet metal layout, CNC machinist, and tread grinding.

1980-1983 US Army, Fort Bragg NC

Combat Engineer, Specialist, E4


2013 - 2015 Reve Academy

Technical Program Lead, assisted with the procurement of computers and CAD software to develop a STEM program for Reve Academy.

2012 - 2013 Onward Bound

Technical Program Lead, assisted with the procurement of computers and CAD software to develop a STEM program within the Stadium View High School.

2006 - 2009 Toastmasters

Area Governor of five clubs with 82 members. Club’s mission is to improve speaking and leadership skills of members.

Club president 2007-2008.

Certified trainer for club officers.

Awarded speaker in humorous and international speech contests.


Bachelor of Science in Mechanical Engineering, University of Minnesota. June 1996.

Additional Education

SolidWorks Simulation Professional, (Advanced FEA: vibration, buckling, drop test, etc), Alignex, Edina MN, 31 Nov – 1 Dec 2016

SolidWorks Simulation, (FEA Fundamentals, element selection, boundary conditions, loads, interpreting results, etc.) Alignex, Edina MN, 28-30 Nov 2016

Statistical Modeling with “R”, Data Camp, Oct-Nov 2016

Photoshop I Course at Hennepin Technical College, Spring 2016

FMEA course with Manufacturing Alliance, May 2015.

Master Classes at ZBrushWorkshop: Production Modeling with Paul Gaboury; Photogrammetry (3D Scanning) with Jeffry Wilson; Jewelry Design with Tomas Witlesbach; ZBrush 4R7 Certification Course with Ryan Kingslien, 2014-2016.

Continuing education at Minneapolis College of Art and Design in a wide variety of art classes: Bronze Sculpting, Graphic Design, Info Graphics, Still Life Drawing, 2009 to 2015.

Online training, VBA for MS Excel, 2012.

SolidWorks Training at Alignex in Edina: All SW Courses, 2010 - 2012.

SolidWorks Composer (Formerly 3DVia) training, at Alignex, 2011 and 2014.

Project Management training, PSI-Project Success, Inc., Atlanta GA. One week course in project management and use of MS Project, 2009.

Mini Master of Financial Management, Saint Thomas University, May 2007.

Finance & Accounting for Non-Financial Manager, Saint Thomas University, February 2007.

FastTrac I New Venture program, entrepreneurial studies, Saint Thomas University, November 2006.

Coaching Teams, Tennant University, June 2008

Dealing With Highly Effective Salespersons, Tennant University, August 2007.

GD&T basic through advance concepts, GD&T Institute, with Dr. Greg Hetland, June 2006.

Finite Element Analysis training, Tennant, 2004

Machine vision training seminar, Society of Manufacturing Engineers (SME). September 1997

Welding Certificate Minneapolis Technical College. 1984.

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