Manufacturing Engineer

Donald A. Beardsley Sr.

Senior Manufacturing Engineer

* ******* ****, *********, **. 01821 Home Phone 978-***-****

**************@*******.*** Cell Phone 978-***-****

Objective: Manufacturing Engineering Position

Four of my last five employers have experienced growth and have been acquired by other companies. The fifth is presently poised for acquisition.

My initial training was in communications electronics and industrial control which combined with my mechanical ability, managerial skills, and experience working in multiple process technologies has provided me with knowledge that I have successfully applied to resolve problems in new products, to keep new product releases on schedule, improve the quality and reduce cost of products.

-My annual salary is typically earned back from cost savings and/or new business within the first year and a half.

-Secured $400,000 in new InterSense business - Listened to customer’s needs and changed material of one part.

-Secured approximately $14,000,000 in new Xylogics business by pushing the PCB and solder process capabilities.

-Improved production documentation, training, assembly fixtures and production tools, reducing assembly times.

-Decrease critical time to market by encouraging inter-departmental teamwork to focus on the release goal.

-Experienced supporting engineering and manufacturing with commercial, scientific, and military products.

-Solved new problems by applying years of experience and unique process knowledge.

-Extensive manufacturing experience in the release and support of quality commercial, military, and scientific products.

-Work effectively across corporate lines with customers and contract manufacturers.

-Experienced in all the typical processes required for new product releases.

-Working knowledge of PCB fabrication and assembly, flex and rigid flex circuits, box builds, rack builds.

-Experienced with acquisition of precision metal and plastic parts, SLA’s, extrusions, castings and sheet metal.

-Vendor evaluation, selection, and vendor quality assessment.

-Product environmental and agency certification testing, fixture design and fabrication, cost reductions

-Solid Works experience.

Employment history:

2006 – 2011 InterSense Inc., Billerica, MA. OEM supplier of Inertial Motion Units and tracking systems

Sr. Manufacturing Engineer Sale pending

InterSense products are used in precision tracking systems, virtual reality systems, flight simulators, platform stabilizers.

Recently secured $400,000 of additional business for an InterSense product. $200,000 from the original customer and an estimated $200,000 from two new customers. A soft tooled plastic base was replaced with a thin walled aluminum investment casting which improved the mechanical stability of the part and greatly improved the electrical performance of the final assembly without substantially increasing the cost or weight of the final assembly.

Worked closely with InterSense customers to define and document modifications required to their custom assemblies for integration of InterSense tracking devices.

Created conceptual mock ups of proposed new products for review by all departments. Having a mock up assisted all groups to visualize mechanical changes, that might be required to add the functionality, mechanical changes, and options desired by each department . Form factor changes could be discussed and quickly added to the mock up if required. This process significantly reduced the time to finalize or kill new products.

2003 – 2005 Xinetics Inc., Devens, MA. Supplier of deformable mirrors and precision actuators

Sr. Manufacturing Engineer Acquired by Northrop Grumman in 2007

One 25,000 sf. bldg. in 2005, five buildings totaling 95,000 sf. today

Responsible for material procurement, including selection and support of CM’s, SMT PCB assemblies, flex circuit fabrication, cable assemblies and in house build and test of rack level drive systems. Introduction of new PCB fabrication vendor and PCB assembly CM decreased product cost approximately 15% and improved quality.

Defined and successfully demonstrated a process to solder a 1,088 position interposer to one surface of a 1.2” x 1.2” cube of ceramic actuator material. The contact configuration on the ceramic cube consisted of 1,088 arrays of (7) .0003” thick by .007” long exposed conductors which needed to be soldered to the interposer/interface cable assembly. This project was part of a phase 2 SBIR program.

2000 - 2005 Giganet Inc., Bolton, MA. OEM supplier of network switches, PCI cards, and ASICS

Sr. Manufacturing Engineer Acquired by Emulex in 2004 for $635,000,000

Obtained coveted OEM supplier status from Dell, HP, and other OEM suppliers with a staff of three. A Materials Manager, Final Assembly/Test person, and Sr. Manufacturing Engineer.

Supported CM’s and vendors to ensure they delivered quality products on time for final assembly and test.

Designed new emissions tight rack mount enclosure working with a local sheet metal vendor.

Assumed the responsibility for all environmental and agency certification testing.

Supported CM activity for assembly of all Giganet products.

1997 - 2000 Aseco, Bolton, MA. OEM supplier of IC Handlers

Manufacturing Engineering Manager Acquired by MCT

Supported build of all IC handlers

Brought contactor assembly in-house resulting in savings of approximately $80,000 per year and a reduction of delivery time from weeks to hours.

Laid out production floor for more efficiently eliminating expense of relocating the business

1984-1995 Xylogics, Burlington, MA. OEM supplier of memory controllers and network servers

Manufacturing Engineering Manager Acquired by Bay Networks in 1995 for $330,000,000

Managed a group of eight Manufacturing Engineers and two equipment maintenance technicians. Provided support for a complete in-house SMT board build, thru hole build, wave solder, environmental test, box build and rack level builds.

Managed all in-house processes, BOM’s, process documentation, equipment maintenance, production equipment programming and support issues from SMT PCB build to box and rack build for many OEM products for Sun, Siemens, Cabletron as well as our own OEM products.

Successfully designed and implemented a multi-track conveyer system in the production area which started at the raw material storage racks and carried material to conveyor box build and test stations, continuing on the conveyor to the packaging area for the inclusion of manuals and customer selected optional items, and on to the shipping area.

Completed fit up and move into a 60,000 sf. and a 35,000 sf. Building, both completed within 3% of budget.

Donald A. Beardsley Sr. Sr. Manufacturing Engineer

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