Engineer Design

David A. Tory

Home: 1-805-***-**** Cell: 1-805-***-**** Simi Valley, CA *****@*********.*** https://www.linkedin.com/in/davidtory

Strategic Profile

Consistent track record of innovative, cost efficient, and well-engineered designs based on the experiences of: Design for Manufacturing and Assembly, Lean manufacturing, Shainin©, Six-Sigma, APQP, Process and Equipment (IQ/OQ/PQ) validations. Outstanding, self-directed, and hands-on Senior Leader with deep technical track record as a Multiple Program / Project Manager, Solution Champion, Change Agent, and Process Advocate.

Seeking a position that utilizes my experiences as a Mechanical/Process or Project Development Design Engineer.

Over 25 years’ experience in Design Engineering in automotive, aerospace, and medical.

28 years’ experience Designing for Plastic Injection Molding, Plastic Part Design and Plastic Materials:

Polyetherimide (PEI)

Polyvinyl Chloride (PVC)

Polyethylene Terephthalate (PETE or PET)

Polyarylamide (PAA or PARA)

High-Density Polyethylene (HDPE)

Polyamide (PA)

Highly skilled and efficient in using SolidWorks (22 years), AutoCAD (25 years), and other CADD Software’s.

Solid background in leading complex product design lifecycles and initiatives from concept through commercialization in close collaboration with top executives, key decision-makers, and subject matter experts (SME).

Skillful delivery of R&D, NPD / NPI (New Product Development / New Product Introduction), through product launch initiatives for automotive and medical platforms, project life-cycle, multi-phase gate, project management, including interpretation of customer specifications and accommodating desired performances.

Employment & Accomplishments

ECA Medical Instruments, Newbury Park, CA (2014-Present)

Privately held $34m leader in manufacturing single-use torque limiting and orthopedic surgery-ready procedure kits. The core competency of ECA Medical is being able to internally design, manufacture, and package plastic injection molded and metal machined components and assemblies.

Provide technical direction, judgment, coordination of, activities for New Product Developments (NPD), as well as support of legacy orthopedic and spine business solutions as part of company’s single procedure surgical instruments and product kits.

Senior Project Development Engineer – (2014-Present)

Design and orchestrate development activities for evolving low cost, single procedure, medical torque limiting instruments which included various types of Plastics, Aluminums, Stainless Steel, Composites, 3D Printing, metal fabrications,

Created an innovative family of torque limiting instruments that directly interface with a surgical drill. This allowed the surgeon to install the fastener (screws) and set the correct torque with the drill, rather than by hand. This technology will be integrated in all future torque limiting designs (see patents below). ECA has been awarded three (3) customer contracts to supply them with this technology and brings an excess of $16m in sales, with others to follow.

This design also, allowed ECA to save 73% in material and manufacturing costs, when compared to a heritage design.

Author test plans, Product, Process, and Equipment Validation and Verification, Design Verification Protocols, based on internal and external critical performance requirements.

Track vendor supply delivery dates, mediate schedule slippage, and resources for testing.

Mentor Jr. and newly hired engineers to provide stability, direction, and confidence, to keep perspective of the overall project. With guidance of understanding QMS ISO 13485:2016, requirements and documentation.

Created equipment design requirements, acceptance protocols, IQ / OQ, and Validation Protocols for custom R&D test equipment.

Evaluate existing instruments and priorities which product would give the best benefit with design or materials changes to reduce manufacturing costs.

Plastic Injection Mold Designer (2018-Present)

Created Prototype and Production plastic mold designs for quick change (5-10 minutes), modular (standardized interface), and versatile (2 to 4 parting within the same tooling), with the option of Ejection Pins or Ejection Sleeves, using the same mold base.

With the quick change modular mold design that I created, saving $275k (annually), by significantly reducing out-sourcing prototype molds and provide faster turn-around for testing design features and materials.

Manufacturing Engineering Manager – Interim (2014-2016)

Reorganized the Manufacturing Engineering Team to be aligned with focus on the equipment and coordinated tooling change overs.

Transferred the responsibility of machine set-up, preventative maintenance, general up-keep, etc. from Production to the Manufacturing Engineering team.

Established SOP (Standard Operating Procedures) for ultrasonic welding set-up, weld strength test verifications, and establish real-time feedback of pass/fail boundaries based on varying equipment outputs.

Initiated Lean Manufacturing philosophy to organize efficient material and processing flow.

Evaluate resource drains, improve on time delivery of new products to market, and enhance resource utilization immeasurably.

EnerSys/Quallion, Sylmar, CA (2009-2014)

$2.8m NYSE traded corporation that designs and manufactures state-of-the-art lithium-ion raw materials, cells, battery packs and new battery chemistries for medical, aerospace and defense industries

Design programs and projects involving mission-critical electronic and electromechanical avionics products for military and commercial aircraft, and electric vehicle platforms. Accountable for evaluating, selection, and commissioning vendors for automated multimillion-dollar Lithium Battery cell fabrication and assembly.

Process Engineer (2011-2014)

Worked with vendors to create equipment design and operational specifications for automated equipment. Coordinated & scheduled supplier for automated Title III equipment & dies.

Create validation test plans, ATPs, and supporting presentations and documents. Documentation that quantified intangible characteristics to validate the down-selection of $3.5M automated equipment.

Used statistics/six-sigma to validate process/part repeatability.

Senior Project Engineer (2009-2011)

With the use of Solidworks, created battery design concepts for military transports and satellites. The largest battery involved over 5000 individual cells, liquid cooled thermal exchange plates, heaters, flex circuits, & 93 electronic controllers.

Kavlico Corporation, Moorpark, CA (1997-2009)

$45m manufacturer of pressure, position, and force sensors and systems for transportation, industrial, aerospace, and defense markets.

Key Product Design Engineer for conceptual designs to high volume production of PRT (Piezo-resistive technology) pressure sensing units/modules for multiple, strategic automotive, heavy equipment, and off-road. Lead numerous interconnected projects involving new product development, testing, commissioning, qualification and validation to enhance the designs robustness and Design For Manufactability (DFM).

Product Design Engineer, Silicon Products (2002-2009)

Coordinate and balance the workload for multiple, simultaneous new products from design concept to high-volume production to meet specific customer requirements.

Create lean product designs that reduce the total number of parts and handling from current production designs. This allowed the company to retain an additional $500K over 3 years.

Planned and oversaw the scheduling and building of customer proof of concept, prototype samples, EV, DV and PV testing units, analysis of the test data, and completing on time and within budget.

Prevented a €3.5 million ($4.75 million) production recall using Shainin© failure analysis process, by rationally detailing that damage from a returned unit did not originate from internal manufacturing processes.

Sr. Products Designer, Industrial Products (1997-2002)

Designed, modeled and drafted individual components, sub-assemblies and assemblies of plastic, stamped metal and screw-machined parts with minimal supervision.

Worked interdependently with Product Engineering, Sales and Marketing for general direction and interpretation of customer requests.

Designed electrical layouts and artwork files for ceramic hybrids and Mylar flex circuitry.

Reflectolite, Inc., Sun Valley, Ca (1996 – 1997)

Design and draft stamped metal parts, plastic injection molded and die cast parts.

Edwards Air Force Base, Edwards, Ca (1995 – 1995)

Civilian contract labor for the United States Air Force.

Intern / Special Instrumentations Group

Spears Manufacturing, Sylmar, Ca (1990 – 1994)

Stress Analysis Engineer / Designer/Draftsman

Test and analyze prototype and production items for any design defects, reliability, and life expectancy using FEA software.

Create conceptual designs of new products – Individual parts through complete assemblies.

Design integrated mold bases for permanent and removable cavities for injection molded parts.

Draft complete tooling and QC drawings for plastic injection molded products.

Price-Pfister, Inc., Pacoima, California (1985 – 1989)

Draftsman/Designer / R&D Laboratory Technician

Design mold bases for Acrylic, PVC, ABS and other thermoplastic injection molded parts.

Create part drawings for stamped metal and screw machined parts.

Test plumbing fixtures and generate validation reports for new product life expectancy.

Research, test and compare competitor’s products for design weakness and durability.

Education

Graduated from Moorpark College, Moorpark California in May 2007, with Associate Degree in Business

Moorpark College

Antelope Valley College

College of the Canyons

Brigham Young University

Moorpark, California

Lancaster, California

Valencia, California

Provo, Utah

Business Management

Mechanical Engineering

Mechanical Engineering

Electrical Engineering

Professional Activities

US Patent No: 7,162,926 Lead embedded pressure sensor January 16, 2007

US Patent No: 9,893,519 Substrate providing electrical communication February 13, 2018

US Patent No: 10,099,354 Flexible connection systems October 16, 2018

US Patent No: 10,343,269 Hypocycloid …gearless …torque limiting device July 09, 2019

Twenty-two patent submittals are currently (Oct 2019) being reviewed for US and European patent approvals

201******** Flexible Finger Connection

201******** Gearless Compact Torque Drive

201******** Gearless Spring Washer High Torque Device

201******** Gearless Spring Torque Drive

201******** Gearless Torque Drive

201******** Gearless In-Line Torque Limited Device

201******** Flexible Connection Systems

120********* Flexible Connection Systems

Core Competencies

● CADD [SolidWorks, AutoCAD, Catia, ProE] ● ANSI Y14 / GD&T NPD (New Product Development) ● Change Management ● Multi-Program & Project Management ● Business Process Development ● Operational Streamlining ● Resource Allocation ● Cost Reduction ● Vendor Relations ● Technology Evaluation ● Performance Metrics ● Research & Development ● ITAR ● Quality Control / Assurance ● GANTT Chart ● cGMP ● ISO 13485 ● ISO 16949

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