Mechanical Engineer

Stephen D. Federico

Wayland, MA *****

E-mail: *****.********@*****.***

SUMMARY

Senior Mechanical Engineer who has the proven ability in applying practical skills to accomplish aggressive corporate goals. Expert knowledge to design, install, debug, trouble-shoot, and repair equipment to maximize productivity and increase machine uptime. Successfully managed cross functional teams for projects of $1.5 M for multi-national corporations with locations in China, Mexico, and Scotland.

AREAS OF EXPERTISE

Capital Equipment Design ~ Project Management ~ Root Cause Troubleshooting

Production Start-up ~ Web Handling ~ Equipment Installation ~ Robotics

Sustaining Manufacturing Equipment ~ SolidWorks ~ 6S

PROFESSIONAL EXPERIENCE

Evergreen Solar Inc., Marlboro, MA/Devens, MA 2007 – Present

Senior Mechanical Automation Engineer

Key member of production start-up team for 2-year-old, ten acre factory which produces $400 M of solar panels annually. Sustained half of the panel fabrication six-axis robotic machinery that produces 175 MW of solar capacity annually. Project manager for installation and debug of internally and externally designed equipment.

• Initiate and direct Flex Picker, Scara, and Cartesian Robot customizations to improve yields, throughput and safety. Factory has exceeded its nameplate goals by 10%.

• Troubleshoot glass panel handling, sputtering, and wafer handling tools to sustain production 24/7.

• Designed unique Cartesian Robot end effector and organized rebuild of six tools while production continued ramp up. Improvements increased uptime of the critical QC tools by 15%.

• Oversee preventive maintenance schedules, spares, and procedures to ensure equipment dependability.

• Determine root cause of equipment failures to reduce downtime and improve dependability utilizing in-depth experience to differentiate between programmable control and mechanical issues.

• Project manager in Wuhan China for installation of a multi-station, in-house designed, quality inspection tool. Organized equipment shipments, spares, on-site installation, and training. Tool was critical to the China Wafer Fab. ramp up. Equipment was operational on time and within the $900 K budget.

• Lead and direct designers to create innovative improvements to OEM and in-house designed tooling.

Presstek Inc., Hudson, NH/ South Hadley, MA 1999 – 2007

Senior Engineer, Manufacturing 2005 – 2007

Directed mechanical maintenance and upgrades for all digital printing plate manufacturing equipment including solvent coater, laminator, slitter, spoolers, vacuum metallizer, sheeter, and various packaging equipment in Hudson, NH plant.

• Upgrades involved in-house design that included unique tooling for a variety of custom equipment.

• Sustained Hudson plant production of over $60 M of printing plate material annually.

• Managed all capital mechanical upgrades to an acquired manufacturing facility that was in a state of major disrepair.

• Team accomplished all goals on time and within budget using coordinated shutdowns which allowed operations to meet production quotas.

• Plating production increased by 30% to $15 M annually with greatly improved quality and high yields.

Stephen Federico (Home) 508-***-**** *****.********@*****.*** Page 2

Presstek Inc. (continued)

Production/ Project Engineer 1999 – 2005

• Directed mechanical engineering for $7 M solvent coater installation. Coordinated contractors, engineers and technicians during installation, debug and commissioning. Project completed ahead of schedule.

• Project manager for unique plate cassette packager. Developed concept and worked with OEM in England to test and debug equipment prior to delivery. Tool output equaled manual output of three operators.

• Project manager for $600,000 next generation plate spooler with packaging system that doubled throughput of previous equipment

RELATED EXPERIENCE

Polaroid Corporation, Waltham, MA

Senior Designer, Capital Engineering

Project manager for $1.5 M film pack assembly project. Developed schedules for machine construction, debug, and delivery to Mexico, Chicago, and Scotland.

• Directed all trade disciplines during equipment assembly, debug and qualification.

• Coordinated all formal documentation including SolidWorks, Pro-E, and AutoCAD data.

• Interfaced with technical support representatives in Mexico and Scotland.

• Monitored project budget and progress to achieve a very aggressive installation schedule.

Lead designer for film coating equipment installations. CAD Users Group team leader.

• Directed design by both in-house and contract personnel for coating, laminating and slitting machines.

• Managed department’s CAD budget and the daily system operation of 11 department-wide SolidWorks CAD stations.

• Management liaison for computer hardware and software issues including justification of all purchases and staff training.

Designer, Capital Engineering

Designed mechanical components and fixtures for film coating, slitting, sheeting and laminating equipment.

• Interfaced with vendors on design issues.

• Consulted with manufacturing personnel to determine machine and safety needs.

• Prepared total graphic documentation for project packages.

• Verified design and detail drawings of drafting personnel.

EDUCATION

Northeastern University, Boston, MA

Associate in Engineering Degree, Mechanical

Wentworth Institute, Boston, MA

Machine Drafting and Design Continuing Education Certificate

PROFESSIONAL TRAINING

Advanced Problem Solving, WPI Seminar, Certificate

Project Management for Manufacturing, Certificate

Web Handling Principles, Oklahoma State University, Certificate

SolidWorks Corporation, Mechanical Solid Modeling, Certificate

Parametric Technology Corporation, Pro-E Solid Modeling, Certificate

SOFTWARE PROFICIENCY

SolidWorks, AutoCAD, AutoCAD Inventor, Excel, Word,

Project Manager, PowerPoint, SAP

U.S. PATENT HOLDER

U.S. Patent No. 6,658,914 B2 - Method and Apparatus for Characterizing

Roll Structure, Issued December 9, 2003

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