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Product Development Engineer

Winston-Salem, North Carolina, 27107, United States
September 27, 2019

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Winston-Salem, NC ***** 336-***-**** NEW PRODUCT DEVELOPMENT

A Product and Technology Development Leader with extensive experience developing new products and processes for the automotive, medical, bedding, and consumer products industries, both as a hands-on leader and an individual contributor.

Key Competencies

• New Product Development • Nonwoven Textile Processing • Project Management

• Product Design • Business Acumen • Engineering Management

• Competitive Analysis • Product Launch • Team Leadership PROFESSIONAL EXPERIENCE

Tempur+Sealy International, Inc Trinity, NC 2017 – 2019

$3.2 billion, world’s largest bedding provider. Tempur+Sealy develops, manufactures, and markets mattresses, adjustable bases, pillows and other sleep and relaxation products. New Product Development Engineer

Technical Lead and Launch Coordinator for Tempurpedic, Sealy, and Stearns & Foster new product launches. Created and documented all product specifications. Provided all critical product data for creation of Law Labels for production items. Approved packaging artwork and created product packaging specifications.

• Led the development and launch of four new pillow lines and four new memory foam beds, achieving industry- leading cooling standards.

• Managed Prototype and Specification Built units for Product Validation testing, including Federal burn requirements 16 CFR part 1632, and 16 CFR part 1633.

• Designated required testing and documented results for new product Claims Substantiation.

• Served as Technical Consultant to legal counsel for examination of applicable intellectual property. ConvaTec, Greensboro, NC 2016 – 2016

A $1.7 billion, global leader in Ostomy Care and Specialty Wound Care technology. Senior Process Engineer (contract position during ConvaTec’s relocation to the Dominican Republic) Managed and maintained all manufacturing equipment for Ostomy and Wound Care production.

• Provided technical, cost effective solutions to project and production issues.

• Defined, developed, evaluated, and implemented operational improvements using Lean principles.

• Led cross-function teams in creation of Process FMEAs, and process development.

• Created methodology to compile and coordinate experiential knowledge transfer for all manufacturing lines moving to Dominican Republic.


Avery Dennison, RFID, Greensboro, NC 2015 – 2015

A $4.3 billion, global leader in printed apparel branding and consumer packaging with integrated RFID tracking. Avery Dennison relocated all its North Carolina facilities to Juarez Mexico. Senior Process and Product Development Engineer

Managed and maintained all manufacturing equipment for RFID production. Designed and developed new RFID technologies, including materials and process technology.

• Created all laser recipes for manufacture of new RFID antennas.

• Oversaw trial and manufacturing runs of laser cut antennas and automated chip attachment.

• Performed troubleshooting and repairing processes on chip attachment line and laser cutter, consisting of nine 900 watt lasers.

• Managed construction of all sample RFID enabled tags for apparel industry.

• Developed and implemented all sample manufacturing equipment and procedures, covering lamination and precision die cutting.

Fortune Personnel Consultants of Greensboro, Greensboro, NC 2013 – 2014 A leader in executive search and recruiting for executive and management jobs, serving Fortune 500 recruiting needs nationally.

Director, Engineering Recruiting

• Placed manufacturing executives and engineering professionals in the nonwovens, automotive, and medical device industries.

Filtrona, Filter Products Division, Greensboro, NC 2012 – 2013 A $350 million global manufacturer of cigarette filters. Business Process Manager

• Managed staff of seven focused on cigarette filter technology development. Directed all activities for samples, prototypes and new product launch. Knowledgeable in specialty filter making processes including: dual and triple filters, coaxial cores, fluted wraps, carbon cavities, carbon dalmations, and capsule insertion. Lorillard Tobacco Co., Greensboro, NC 2009 – 2011

A $6 Billion manufacturer of tobacco products.

Research Engineer

Developed new technology yielding safer tobacco products.

• Developed a filtration concept that dramatically increased filtration efficiency using existing materials. Filter length decreased by 56%.

• Developed new method and device for capturing and separating cigarette smoke for safe e-cigarette flavor augmentation.

• Created automated smoking machine to simultaneously measure smoke temperature, pressure drop, and chemical analyte production. First such device and measurements known in cigarette industry.

• Created GC / Mass Spec method to analyze for 20 chemical analytes in a single run, reducing test time by 55%. WILLIAM C. ATTKISSON PAGE 3

Vita Nonwovens (Vitafoam, Inc.), High Point, NC 2005 – 2007 The U.S. Division of British Vita. This business was put on up for sale in 2007. Product Development Manager / Product Engineer

Developed nonwoven textile products for the bedding, automotive and air filtration industries. Extensive experience with textile opening, blending, garnetting, carding, cross lapping, web impregnation, needle-punching, calendering, lamination, converting, slitting, high-loft thermal bonding, and roll wind-up.

• Directed design engineering staff of 3 with a $750K development budget.

• Modified existing processes and specified production equipment to meet and exceed acceptable capacities and capabilities.

• Developed first bedding flame retardant materials in the US capable of meeting federal fire retardant standard, 16 CFR part 1633 (2007), along with customer specific requirements.

• Created all product brand names, naming methodology and brand logos for packaging, labels and marketing brochures.

Lydall, Inc., Hamptonville and Winston-Salem, NC 1995 – 2005 A $400 Million manufacturer of engineered filtration products and industrial thermal insulation solutions. Senior Research and Development Engineer, Charter Medical (division of Lydall, Inc.), 2003 – 2005 Recruited to this Lydall Division to develop specialized blood filters and disposable containers for bio-pharmaceutical manufacturers. Served as a change agent by challenging existing methods of operation and implement new solutions and improvements. Extensive experience with textile carding, needle-punching, calendering, lamination, converting, slitting, and thermal welding.

• Managed an engineering, design, and technical staff of 7 including a $5 million product design budget.

• Directed all launch activities for new parts and products.

• Developed automated manufacturing line for assembling disposable biopharmaceutical media containers.

• Developed a co-extruded single film layer, replacing multi-layer plastic film processing, simplifying manufacturing, reducing process errors by 80% and improving product qualification properties. Product Technology Manager/Advanced Research, Lydall Automotive, 2000 – 2003

• Served as a change agent by challenging existing methods of operation and implement new solutions and improvements. Extensive knowledgeable of nonwoven and metal processing: textile opening, garnetting, carding, cross lapping, web impregnation, needle-punching, calendering, lamination, converting, slitting, roll wind-up, and die cutting; Metal die-cutting, lamination, hot and cold molding. Specified processing equipment for new product lines. Modified existing processes and specified new processes.

• Created and managed a product development engineering team of 10, consisting of engineers, CAD designers and testing/prototype technicians.

• Developed 3 new product lines for automotive thermal and acoustic insulation markets, each generating over

$10 million in revenue in their first year.

• Managed all intellectual property activities on new and existing patent/trademark activity (3 new patents/5 trademarks).

• Led automotive advanced research project and developed power generating automotive heat shields utilizing thin-film thermo-electric modules. Managed relationship with Research Triangle Institute for builds and intercompany contractual development.


Manager, Product Testing and Engineering Launch, Lydall Automotive, 1998-2000

• Managed all product testing, overseeing 3 engineers and 4 technicians.

• Brought all testing lab procedures and equipment up to American Association for Laboratory Accreditation

(A2LA) standards and earned A2LA, ISO9001 and QS9000 certifications.

• Created Program Engineering Groups aligned with key product lines providing in-depth technical support.

• Developed instrumentation and test procedures for ranking under-hood and underbody heat shield materials and designs. Adopted as the SAE standard across the automotive industry.

• Validated all new processing equipment for manufacturing processes. Lead Design Engineer, Lydall Automotive, 1995-1998 - Promoted from Design Engineer in 1996.

• Developed, implemented, and maintained standardized Release Package system to manage development of new parts to customer specifications and document for release to manufacturing. o Release Package included: Design Records, Process Flow, DFMEA, PFMEA, Control Plans, Engineering Drawings, Engineering Approval, Engineering Change Notifications, Gage R&R, Qualification Testing Records, Appearance Approval Report, and Part Submission Warrant

• Designed automotive heat shields; managed design/build for prototype tooling; created and managed all engineering cost quotes for new parts.


Bachelor of Science (Cum Laude), Mechanical Engineering North Carolina State University, Raleigh, NC

Pi Tau Sigma, Engineering Honor Society

North Carolina State University, Raleigh, NC

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