Process Engineer

MICHAEL COZENS

*** *. ******, ****, *******. ****1

Phone: 480-***-****, ********@*****.***

SUMMARY OF QUALIFICATIONS

Chemical Engineer with 20 years of experience in electronics manufacturing including experience in PV and printed circuit applications. Proven success in implementing productivity enhancement systems such as TQM, Six Sigma, and Lean Manufacturing, as well as CAPM certification. Excellent management skills and strong team player. Proficient computer skills, including MS Office, PLC/ladder logic programming and JMP. Ability to build robust processes and interact with all levels within the organization to exceed core objectives.

WORK EXPERIENCE

PrimeStar Solar, Arvada, CO 01/2009 to 05/2010

Startup solar panel company (reduction in workforce)

Sr. Process Engineer

Wet chemistry process engineer. Responsible for spray coating, photo and other chemical processes.

• Multiple process owner. Established optimal operating parameters, generated work instructions, mentored technicians, supported day to day operations.

• Directed mixing operation. Created work instructions, lab procedures, and trained technicians on the operational aspect of their roles. Performed certifications and implemented control charts.

• Documented technical specifications for incoming chemicals. Conducted vendor audits with SQE to ensure compliance and assess quality systems.

• Responsible for equipment specification and buyoff, startup, documentation.

• Conducted DOEs to drive process improvement. Analyzed data and presented to management.

Matheson Tri-Gas, New Johnsonville, TN 03/2008 to 09/2008

Manufacturer of UHP semiconductor gases (left due to excessive travel)

Project Engineer

Project involved the installation and startup of a new manufacturing process producing UHP semiconductor gas (H2Se) for solar panel manufacture. Responsible for equipment specification and purchase, vendor interaction, P&ID work, process qualification.

• Managed database of equipment and parts requirements in support of the ongoing installation.

• Produced documentation for specific equipment: specifications, PMs, spare parts requirements.

• Responsible for maintaining and updating P&ID drawings as changes occurred.

• Worked with contractors on interpretation of installation specifications and drawings.

Rogers Corporation, Chandler, AZ 06/2002 to 10/2007

$500M manufacturer of specialty materials (position was eliminated when business went to Asia)

Technical Service Engineer (2 yrs)

Worked with customers to provide maximum value from Rogers materials. Developed and maintained strong business relationships and assisted in process development and new product introduction.

Senior Process Engineer (3 yrs)

Responsible for performing root cause analysis and corrective action activities for all roll to roll manufacturing processes, including coating adhesives, drying and lamination in a plant with 150 employees.

• Managed project that increased line speed by 80%

• Lead Kaizen event to decrease setup time from 3 hours to 1 ½ hours.

• Developed and qualified new epoxy based, halogen free adhesive system.

• Implemented scrap reduction program that resulted in 40% savings.

• Employed Six Sigma and Lean Manufacturing tools to accomplish continuous improvement objectives.

Innovex, Inc./ADFlex solutions, Inc., Chandler, AZ 3/1999 to 12/2001

Manufacturer of printed circuit boards (position was eliminated when facility was closed)

Engineering Manager

Engineering manager for all chemical manufacturing processes, including continuous web processing in etch and copper plating. Directed and managed startup of chemical operations in Thailand facility. Direct reports included 6 engineers, 3 engineering assistants and lab personnel in a plant with 600 employees.

• Responsible for all activities involved in bringing new processes online and sustaining production.

• Served as the companies’ expert in the maintenance and upgrading of process automation, software controls, HMI issues.

World Circuit Technology, Simi Valley, CA 05/1998 – 03/1999

Manufacturer of printed circuit boards (Expat assignment was cancelled when project was put on hold)

Project Engineer

Project involved the design, installation and start-up of 100,000 sq. ft. automated flex circuit shop in Malaysia. Responsible for all plating equipment, analytical lab, waste treatment system and DI water system. Performed requirements gathering and generated design specifications for 8 large automated processes and automated waste treatment facility. Responsible for contract review and machine buy-off.

• Conducted training for 14 Malaysian engineers over a 2 month period. Spent 6 months offshore at 2 production facilities in China.

• Tasked with meeting quality objectives in wet process and plating.

• Implemented data collection, SPC, analytical controls, documentation, certifications and DOE principles.

ADFlex Solutions, Inc., Chandler, AZ 08/1993 – 05/1998

Manufacturer of printed circuit boards (Left for expat opportunity)

Senior Process Engineer/Process Engineer

Developed processes and maximized qualitative throughput for all plating processes in a +200 million dollar, ISO 9000 certified flexible circuit factory with 800 employees. Provided direction to 3 process engineers and laboratory personnel to ensure that plating processes met company objectives.

• Implemented SPC for all processes and incoming QC for all chemicals.

• Researched, designed and installed electroless nickel/immersion gold process producing 95,000 sq. ft. of product per week.

• Designed and installed 3 automated plating lines and 3 hand lines, including requirements gathering, software generation, user interface, design and implementation of PLC controls.

• Developed outline and engineering specifications for purchase and install of automated roll-to-roll electrolytic copper/tin plating line utilizing 24” web.

DuPont Electronics, Raleigh, NC 1992 – 1993

Contract employee

Process Development Engineer

Dynamics Research Corp., Wilmington, MA 1990 – 1992

Developed terminal print heads (position was eliminated when facility was closed)

Development Engineer

EDUCATION

Bachelor of Science-Chemical Engineering, University of Maine, Maine, 1981

Green Belt Six Sigma Certified, Rogers Corp, 2003

Computer Language Courses, University of Lowell, 1988-90

Semiconductor Processing, University of Lowell, 1990

PROFESSIONAL TRAINING

CAPM Certification, PMI, 2006

Shainin Training, 2004

PLC Programming (SLC-500). Allen-Bradley, 1995

PLC Programming (PLC-5), Allen-Bradley, 1994

Focus on Data (Six Sigma), DuPont QM & TS, 1993

Strategy of Experimentation (DOE), DuPont QM & TS, 1993

Primary Imaging, DuPont QM & TS, 1992

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