Michael J. Mahaney

P.O. Box ****; Edgewater, FL *2132

717-***-**** (cell)

dget4t@r.postjobfree.com

Professional Summary:

• Production Manager – Responsible for manufacturing plant configuration and utility definition for production machinery and product assembly; interacted with vendors for value added products and workforce utilization

• Project Engineer - Planned and designed lean product manufacturing process, supervised staff to define resource needs, activities to achieve milestones and resolve manufacturing bottlenecks; defined user interface activities; defined replacement parts, routine and periodic maintenance schedule for plant staff; defined equipment envelope, “hand-shaking” functioning parameters for product handoff and acceptance testing with verification artifacts

• Mechanical Engineer – Machine and component design for product assembly; mechanical, electrical and pneumatic mechanisms for product manipulation and transport; technical research for quality product manufacturing applications, translating customer requirements into equipment/product manufacturing capabilities

Experience:

07/2011-10/2011 Project Engineer

FLIR-ICX Tech Elkridge, MD

• Production Manager of the assembly and test of the Combat Outpost Surveillance and Force Protection System

• Significant Accomplishment(s)

o Lead junior engineers and technicians in integration of surveillance equipment into aerial transport container

o Defined a strategy to implement activities and resources to meet milestones, acceptance test and delivery

• Engineering review of drawings, solicitation of bids for part manufacture, met with vendors to resolve issues

• Designed parts and assemblies in SolidWorks 2011 format, reviewed drawings in SolidWorks PDM

• Gave guidance to a team of technicians and manufacturing staff with form, fit and function issues arose

• Engaged with engineers and designers to resolve technical problems and conflicts for proper resolution

• Participated in acceptance test for requirement validation and customer approval for fielding

01/2009-05/2010 Production Manager

Science Applications International Corp. (SAIC) Orlando, FL

• Production Manager of the assembly and test of the Common Driver Trainer (CDT) and assembly facility

• Negotiated with construction company to upgrade facility with power and HVAC for CDT manufacturing

• Participated in prototype requirements and design reviews with the customer, submitted monthly progress reports

• Planned and trained technical staff needed to achieve Lean productivity methods and 5S practices

• Met with OEM vendors to review quality procedures and minimize part variation prior to delivery

• Developed a value stream of processes with staff and standardized parts for improved metrics and BOM

• Design of CDT mechanical in SolidWorks 2010 and electrical harnesses in AutoCAD for customer delivery

• Established milestone chart with man-hours and staff skill level to meet delivery dates and requirements

• Solicited quotes from multiple vendors for make parts and assessed their quality procedures for best value

• Coordinated and assisted with equipment installation with mechanical and electrical technicians

• Provided product support after delivery to maintenance staff and customer to insure product quality

10/2006-03/2008 Project Engineer

BAE Systems York, PA

• Project Engineer for design and development of prototype DOD track vehicle recovery equipment

• Defined and authored mechanical-electrical equipment Contract Deliverables Requirements List (CDRL)

• CDRL defined equipment footprint, components, mechanical and electrical requirements, reliability levels

• Designed preliminary vehicle prototype winch component parts on Pro Engineer Wild Fire 3.0 with FEA

• Determined equipment testing levels and artifacts for verification of compliance to MIL-STD-810

• Presided over peer review meetings of equipment design specifications and approval of stake holders

• Researched cost of OEM and manufactured parts from RFQ’s for budget considerations and BOM

• Participated in design reviews with team managers and customer to verify that requirements are met

• Met with Production, Quality Assurance and Maintenance for input and discussion for product improvement

• Interfaced with Subcontract Administrators, Purchasing, Configuration Management (CM), Manufacturing staff

• Met milestones for prototype product development, in-house-testing and field testing with customer approval

• Reviewed inadequacies of past equipment designs to identify root causes and potential solutions

09/2003-06/2006 Student

Madison Area Technical College Madison, WI

• AC & DC Electrical theory, Allen Bradley PLC Ladder Logic, C++ programming of PIC Chip sets

• Cable and harness assembly, PCB design and assembly

• SolidWorks

• Quality Management including:

o Team Building, Understanding Organizational Change, SPC for production control, Employee Involvement

05/2000-12/2001 Project Engineer

Thomson Multimedia Inc. Lancaster, PA

• Participated in turn-key construction of a high speed television tube manufacturing plant in Mexicali, Mexico with Industrial, Electrical and Lean Engineer team including construction and installation contractors

• Member of plant construction planning team for plant layout, construction management and utility configuration

• Supervised the design, development, layout, installation and testing of manufacturing capital equipment

• Reviewed and critiqued equipment designs in Pro Engineer 2000 for cost estimation and efficient product handling

• Met with equipment vendors to assess production capability of machinery and review specifications

• Established criteria for acceptance testing of capital equipment and to meet production capability requirements

• Wrote Allen Bradley PLC programs for equipment product handling and counting

• Participated in Project Management reviews to establish activities and milestone schedule for plant startup

• Defined potential bottle necks for production and devised a plan to reroute or dispose of product, if necessary

• Cross trained production staff to best utilize their efforts, support other staff and maximize total product flow

• Designed TV band gages to verify banding machinery is working within acceptable production tolerances

• Discussed Failure Mode and Effects Analysis (FMEA) with vendors and technical team to improve quality

• Recommended maintenance parts for machinery to be in the ERP system and suggested replacement cycle

• Initiated Kaizen processes and events for Lean Manufacturing to better streamline tube production

12/1998-2/2000 Mechanical Engineer

UDLP York, PA

• Investigated mechanical, hydraulic and electrical design problems of the Army’s M88 tank recovery vehicle

• Assessed manufacture and assembly techniques that contribute to mechanical failure and report findings

• Interviewed assembly and fabrication personnel to determine and define the root cause of reported problem

• Analyzed vehicle systems to determine root cause failure of failed components, spoke with vendors if necessary

• Calculated stress and strain of vehicle drive train to anticipate if manufacturing modifications would create issues

• Reviewed and reworked vehicle electrical schematic to resolve equipment function and grounding problems

• Initiated an ECP and NOR from engineering analysis to improve vehicle quality and assembly

11/1996-11/1998 Project Engineer

Commonwealth Scientific Corporation Alexandria, VA

• Developed turn-key high vacuum (103 – 105 Torr) material handling and metal deposition systems

• Designed mechanical mechanisms with AutoCAD and Pro Engineer to handle products in a clean room

• Managed quotes and delivery of equipment from vendors for prompt delivery and acceptable cost

• Resolved part function problems due to design or manufacturing; documented corrective action for improved quality

07/1990-10/1996 Mechanical Engineer

VSE Corporation Alexandria, VA

• Evaluated electrical/mechanical devices for the military to confirm design integrity and manufacturability

• Designed, in AutoCAD, prototype mechanical enhancements to equipment with GD&T and BOM

• Equipment testing at Ft. Belvoir, VA to validate design changes are field equipment ready

03/1986-06/1990 Project Engineer

Enviromarine Systems Laurel, MD

• Designed and developed a turn-key automatic assembly machine for a nerve gas detector air filter consisting of a multi-station system with electro-mechanical and pneumatic mechanisms to move and assembly the filter

• Led debugging and upgrading of system to establish acceptable product quality and consistent production capacity

• Directed installation and acceptance testing at customer’s facility to produce filters meeting specified requirements

05/1984-02/1986 Mechanical Engineer

Frederick Manufacturing Frederick, MD

• Designed mechanical mechanisms for a pipe coupling assembly machine

• Designed test machinery to simulate canvas and synthetic fabric wear of Postal mail bags

Education:

Program Management Professional Certification Prep MCWD&CE 2011

Foundations of Lean SME 2010

Planning Lean Manufacturing Layouts SME 2010

Failure Mode and Effect Analysis (FMEA) ASQ 2010

Root Cause Analysis (RCA) ASQ 2010

Certificate of Quality Madison Area Technical College 2004 - 2006

Electrical Technology; 93 semester hours Madison Area Technical College 2003 - 2006

Mechanical Engineering; BSME Pennsylvania State University 1979 - 1983

Skills:

MSWord, Excel, Power Point, Project, Visio, AutoCAD 2010, SolidWorks 20

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