Electronic Test Engineer
Resume:
ROBERT F. KARCHER
Bethlehem, CT **751
************@*******.***
CAREER OBJECTIVE: Seeking a position with the opportunity to best utilize and further develop my
ELECTRONIC ENGINEERING, MOTION CONTROL, SENSOR
DESIGN, MANUFACTURING, SUPERVISORY and HANDS-ON
SKILL-SET capabilities with an eventual leadership position.
WORK EXPERIENCE: TOMTEC Inc.
Hamden, CT 2008 – Present
PRODUCT DEVELOPMENT ENGINEER
Primary Responsibilities: Prepare and process of documentation, provide technical assistance and
hands-on engineering support to facilitate a timely resolution to
manufacturing performance issues. Design tooling and re-design existing
and future production products to meet medical industry requirements.
Major Accomplishments:
• Established work-place instructions on six existing product lines, trained
and cross-trained manufacturing personnel on proper assembly and build
methods.
• Designed tooling for proper alignment methods for manufacturing.
• Engineered and optimized stepper motors and software for greater
accuracy and quicker cycle times to meet medical industry standards.
• Eliminated audio harmonics from motion control devises through
proper mounting and unique drive and step methods on new
Formatter™ multi-axis pipetting system.
• Visited customers and performed start-ups on purchased products and
discussed future needs from the customers.
WORK EXPERIENCE: TIMKEN U.S. CORPORATION / THE TORRINGTON COMPANY
Torrington, CT 2002 – 2008
ELECTRO-MECHANICAL TEST/ DESIGN ENGINEER
Primary Responsibilities: Managed customer base in the product development process and engineered
custom Magnetic Hall-Effect Speed and Positioning Sensor Circuits
and Prototype Assemblies according to customer requirements and Timken
process capabilities. Designed Electro-Mechanical Test Systems, Tooling,
Wrote Test Procedures and Supervised the Engineering Test Lab to meet
customer delivery schedules and product qualifications. Researched
Materials and Manufacturing Methods to minimize Production Cycle
Times.
Major Accomplishments:
• Launched five speed and positioning Magnetic Hall-Effect Sensor
applications from concept to final production phase for the Military,
Automotive, Industrial and Commercial markets.
• Designed new automated sensor test station which consisted of high
resolution X-Y-Z linear slides and ½ hp servo motor capable of rotating
to speeds equaling 10,000 rpm to meet Automotive speed requirements
and application test simulations.
• Implemented a close-loop magnetizing system and method which
magnetized, validated gauss levels and date-code stamped magnetic
target assemblies for shipment.
• Designed and built three Electronic/Mechanical programming test
stations for pre-approved vendors to program Timken ASIC and
validate at time of circuit assembly, before and after over-mold
process and production receiving inspection.
• Performed Tear-Down Analysis by Developing a Test Plan and
designed custom electronic feed-back circuits to determine
performance accuracy of the Timken Magnetic Sensor Encoder and
competitor’s Optical Sensor Encoder which resulted in a greater market
offering with the Servo and AC Motor manufactures.
• Performed magnetic material analysis on bonded and silk-screen
Neodymium magnet materials and determined optimum magnetizing
parameters and implemented new magnet material and processes
throughout entire Magnetic Hall Effect Sensor Product Line for
enhance performance and minimized production errors and cycle times.
• Developed drawing packages through Geometric Dimensioning &
Tolerancing (GD&T) format for in-process tooling, prototype
assemblies and production test fixtures.
• Held Engineering responsibility for all customer returns through an
8-D Corrective Action Process.
WORK EXPERIENCE: HAYDON SWITCH & INSTRUMENT CORPORATION
Waterbury, CT 1998 - 2002
APPLICATION ENGINEER/NEW ENGLAND SALES MANAGER
Primary Responsibilities: Design and create Custom Electronic, Rotary and Linear Solutions for new
and existing customers in the New England Sales district based upon core
Linear Actuator and Rotary Stepper Motor Product Line. Apply
Engineering Principles for Stack-Up Tolerance Analysis and Technically
Interfaced with Customers, Vendors and Outside Sales Representatives.
Major Accomplishments:
• Designed and created three special product lines consisting of High
and Low resolution X-Y Tables, Oscillating and Dual Motion devices.
• Designed and implemented new Captive-External Linear Actuator for
a Hand-Held Medical Pipette which produced $750k of annual sales.
• Implemented new coil design with on-board termination to gain Motor
Efficiency for Battery Sourced Applications which consisted in a larger
bobbin fill factor and more Ampere turns to produce higher output
torque and forces within standard frame size motors.
• Designed new liquid-cooled magnetizing fixture with magnetic pole to
shaft orientation which minimized production cycle time and fixture
fatigue for the Advanced Manufacturing Team.
• Implemented Linear and Rotary on-board feed-back with Hall-Effect,
Optical Interrupt and Mechanical Micro-Switch to determine end-of-
stroke and linear and rotary home position.
• Managed and Supervised four Technicians in the Prototype/Test Lab
which produced an average of fifty custom prototypes per month.
• Traveled to ten represented districts per year to technically assist the
territory and boost annual sales.
WORK EXPERIENCE: NORTH AMERICAN PHILIPS CORPORATION /
AIRPAX AUTOMOTIVE DIVISION
Cheshire, CT 1988 - 1998
ELECTRO-MECHANICAL RELIABILITY TEST ENGINEER
Primary Responsibilities: Responsible for Automotive product reliability validation testing on 6 product
lines having a combined annual sale of $72 million. Supervised Test Lab work
flow and eight Technicians. Maintained electronic test equipment calibration
schedules, Purchased capital equipment and design custom electronic circuitry
for product reliability validation testing.
Major Accomplishments:
• Designed and developed specialized bearing tester to evaluate and
analyze bearing drag torque with selected greases before and after
automotive reliability stresses at temperatures equaling -40°c to 150°c.
• Designed and implemented in-line test system to evaluate electro-
magnetic torque variations.
• Established Engineering Lab and Life Durability Department from
ground up to test and develop custom rotary and linear permanent
magnet stepper motors.
• Member of the Design Team which implemented a second and third
generation Idle Air Control Valve, through DFMEA process which
consisted of fewer components, integrated components and greater output
force to meet customer requirements and higher volume production needs.
• Designed and implemented in-line high voltage/high frequency tester
for detecting shorted turns within a 5,000 turn coil/bobbin assembly.
WORK EXPERIENCE: STONE SAFETY CORPORATION
Wallingford, CT 1986 - 1988
ELECTRICAL ENGINEER
Primary Responsibilities: Designed, tested and trouble-shot DC motors and AC/DC electronic
controlled drives for the Rail Industry.
Major Accomplishments:
• Developed custom circuitry and wrote test procedures to standardize test
methods and validate High Voltage AC/DC Converters with in-line and
final test stations.
• Reorganized Test Lab internal systems by implementing Test Lab
Request, Corrective Action Forms and Trouble-Shooting Log Book to
minimize trouble-shooting process.
EDUCATION: WATERBURY STATE TECHNICAL COLLEGE
Waterbury, CT 1984 – 1986
Majored in ELECTRICAL ENGINEERING.
SPECIAL COURSES: Introduction to Lean Six-Sigma, Geometric Dimensioning & Tolerancing
(GD&T), Design For Manufacturing Assembly (DFMEA), Project Time
Management, Project Cost Management, Project Risk Management,
Management/Supervisory Training and Microsoft Office Programs.
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