Independent Quality/Manufacturing Engineer - Austin, Texas 2006-present
Worked for Medical, Defense and Commercial Manufacturing Companies on a contract basis. Products job responsibilities included the following. Developing and executing Manufacturing Quality protocols (IQ/OQ/PQ) for Class 2 and Class 3 Medical devices; Providing sustaining Engineering Support for manufacturing operations including updating Design History Files; Investigating Manufacturing defects and trends using structured methodology in cross functional teams including Failure Mode Effects Analysis (FMEA); Root Cause Corrective Action (RCCA). and improving Preventive Maintenance for Manufacturing Machinery using Plan Do Check Act (PDCA) methods per Deming-Shewhart.
Products include electromechanical assemblies, plastic and metalliclaser machined. formed and molded parts for stent and wound care products, surgical staples and ligation clips, and related hospital equipment. Provided floor support for Injection Molding, CNC machining, and Electromechanical Assembly operations and related processes. Developed processes for laser machining and welding of stent and catheter cardiovascular products.
Provided incoming inspection support for electronic and electromechanical assemblies used in Space Rocket Motor Control. Evaluated heat treat conformance data and material testing results for mechanical parts.
Supported production of Satellite Systems including gyroscopes, and related hardware. Solved technical problems in electromechanical assembly and test. Bought upgraded hand and power tools for electromechanical assembly.
Developed manufacturing processes for secure communications hardware for military applications per IPC-A-610C. Participated in IPT groups that developed Circuit Card Assembly designs. Developed manufacturing processes for Military Hybrids per Mil-Std-38851 and Mil-Std-883C, and IPC-A-610C. Processes included eutectic and epoxy die attach, wire bonding, parallel gap welding, and hermetic sealing.
Project Quality Manager/Engineer Confidential, Burlington, VT 2003-2005
Implemented IPC-A-610C and IPC/WHMA-A-620 specs for a Vendor Supply Chain Fire Control System for a 155 MM howitzer. Surveyed Vendor Facilities and conducted Technical Reviews of Electronics Designs and Mechanical Components.
Senior Advanced Manufacturing Engineer, Confidential, 2001-2003
Implemented improved manufacturing processes for RF countermeasure CCA's including SMT/BGA placement, soldering, rework, and inspection. Participated in IPT meetings; performed DOE/Taguchi Methods on Advanced Soldering Methods for large SMT Connectors. Held SECRET, COMSEC, CRYPTO, clearances.
Independent Manufacturing Engineer/Consultant, Austin, Texas 1989- 2000
Assignment tasks included SMT, BGA, PTH; Electro Mechanical Assembly Process Development, Capacity Analysis, Time and Motion Study, Root Cause Corrective Action (RCCA), ISO 9001 Implementation and Procedure Development, Design of Experiments (DOE), Facility Layout, Composites Assembly, and Supply Chain Management.
Products included Medical Products, Space Flight Module Assembly, Composite Parts, Injection Molding, Sheet Metal, and Machined Parts; and Explosives.
Identified improvements for existing SMT, PTH and electromechanical production facilities including first pass yield improvement and cycle time reduction, and Developed processes for advanced Electronic Packages. Developed Labor Standards and identified and procured capital equipment ($5,000,000+).
Worked in a wide range of corporate cultures and organizations. Saved clients over $5,000,000 in cost avoidance and reduction. Improved manufacturing yields, methods, equipment, and operator performance. Negotiated supply chain contract terms with internal departments and contract manufacturers.
Manufacturing Systems Analyst, Confidential, Seattle WA 1986-1988
Provided DFM Support for the Development of large Electronic and Mechanical systems for Ballistic Missiles. Participated in Design Team PDR, CDR efforts and interfaced with suppliers to achieve program goals in Machining, Sheet Metal, Composites, Castings, Electronics, and Cable Design.