Andrew Matrullo Email & Phone Number

Attleboro, Ma, Us

As the Design Engineer Manager, I’m responsible for leading a team of engineers to achieve outlined goals to meet rigorous automotive customer requirements for design performance, quality, and cost. As part of the North America Vehicle Business I focus on the design & development of electro-mechanically orientated components for safety critical products.- Developed technical roadmap for high voltage contactors in North American EV platforms, focusing on regional supply, manufacturability, and design best practices to mitigate global supply chain risks.- Led design team through successful launch of 1st and 2nd-gen High Voltage Distribution Box contactors for Battery-Electric Passenger Vehicles leading to on-time PPAP and SOP.- Conducted complex benchmarking for battery protection projects to support marketing and engineering for accurate product proposals and quotations.- Mentored design engineering team on IATF 16949 compliance, leveraging QMS expertise.- Established technical recruiting process for improved talent pipeline through university intern programs

Carpinteria, Ca, Us

- Mentored a team of 7 engineers, enhancing efficiency with AIAG Core tools like MSA, PFMEA, and reliability analysis. - Managed North American capacity expansion, relocating and requalifying 3 production cells for high-voltage contactors.- Reduced core epoxy dispensing process hours/K through error-proofing, achieving a $300K cost avoidance.

Carpinteria, Ca, Us

- Conducted multi-factorial DOE to optimize thermoset epoxy reliability to meet AECQ200 thermal stress requirements- Established global standard for flexible hermetic sealing in high-voltage contactors by collaborating with cross-functional experts on material and process selection for epoxy dispensing.

Attleboro, Ma, Us

- Led process development for next-gen digital pressure sensor in anti-lock braking and stability control modules.- Designed and qualified a manufacturing process flow with a $500K capital equipment budget.- Reduced quality risks and manufacturing costs through FMEA-guided automated equipment design.- Developed an automated flexible bulk feeding system with high-accuracy optical inspection, lowering labor hours.- Worked with design and quality teams to create a low-cost sensor design using DFSS, minimizing manual assembly.- Increased yield by 15% by guiding a global engineering team through new product development and improvements using DMAIC- Served as Sensata Technologies audit lead, securing customer approval with no major findings during audit

Attleboro, Ma, Us

- Designed manufacturing process and equipment for the industry’s smallest brake pressure sensor in stability control platforms.- Led global team to install and qualify the first manufacturing cell with $3.6MM in automation equipment.- Developed robotic handling for resistance welding, boosting throughput by 1.5MM units/year and saving $200K.- Used DMAIC problem solving techniques to lead continuous improvements, increasing production yield by over 10%

Attleboro, Ma, Us

- Developed manufacturing process for next-gen Microfused Strain Gauge brake pressure sensor, with over 20 million units produced.- Created Automated Machine Vision Inspection, reducing inspection yield loss from 4% to under 0.1%.- Executed manufacturing qualification for new sensor production within 6 months ensuring on time PPAP and SOP- Six Sigma Green Belt Champion, improving fault detection in laser welding for fuel rail pressure sensors.- Key member of Global Process Team, standardizing laser welding best practices across global sites

Blackfriars, London, Gb

At Unilever, I was responsible for developing and managing a website to streamline and automate a data input system to provide monthly reporting numbers for the Supply Chain Senior Leadership Team. I also created and managed a project plan for a migration to a global reporting platform.

Bachelor Of Science (Bs), Manufacturing Engineering

Master Of Business Administration (M.B.A.)

Bachelor Of Engineering - Be, Manufacturing & Mechanical Engineering