I provide project management, manufacturing and design expertise, and team leadership experience, in addition to various technical and process experience capabilities, in addition to developing the manufacturing sustainability expertise within NCDMM.

Redesigned and improved enclosures for air cooled medium voltage drives. Redesigns and improvements including; design modifications to increase quality and reduce cost, design consolidation across product lines, implimentation of design for manufacture methodologies, integration of design methodologies into current product offerings to enhance field servicability and reduce the cost of manufacture.

Senior Mechanical Engineer / Project Manager / ProEngineer AdministratorCreated capital machine ($30K – $800K cost) and tooling designs ($3K – $500K cost) used to deburr and polish internal and external metal part geometry. Tracked design and build project schedules and budgets. Maintained and developed robust product modeling through utilization and training of best practice modeling techniques. Communicated with customers to understand their machine and process requirements. Assisted service personnel as technical point of contact for field upgrades and problem resolution. Performed various project management functions including: coordinating customer visits (international and domestic), financial tracking, budget and timeline reporting, build schedule monitoring. Administrator of ProEngineer Design Software including: software installation, determining training requirements, training, efficiency study / determination, model troubleshooting, configuration management.• Developed and transferred machine build from US build locations to China and Ireland, resulting in 50% reduction in machine delivery to Asian customers, and a 25% reduction in machine cost.• Consolidated several diverse product lines from multiple locations within US to 1 central location. Reduced overhead cost by over $4M annually and reduced average build time by 15% through utilization of stringent, centralized, engineering control.• Created standard product bill structures, allowing for “single number” ordering within SAP.• Redesigned entire product line, encompassing $3.1M in cost, reducing build cost by over 10%.• Thrived in culturally diverse environments with foreign nationals. Worked extensively with Chinese nationals, in US and abroad, in role of supplier and colleague.

Weapons Engineer / Mechanical Engineer IIIDesigned and procured projectiles and projectile handling systems for high velocity test gun. Projectile design parameters included stability, drag, range, time of flight, range, and gun launch survivability. Developed monthly project status reports and distributed to applicable government agencies.• Utilized Finite Element Analysis design experience, reducing projectile flight weight and increasing launch durability to withstand high G projectile launches. • Developed and procured projectile components, both instrumented and un-instrumented, that set a world distance record for a projectile fired from a chemical gun. • Specified and incorporated instrumentation packages required for launch and flight data acquisition. This instrumentation allowed internal ballistics to be directly recorded for the first time in test history (as opposed to back calculated from the external ballistics).• Developed and procured projectile components, both instrumented and un-instrumented, that set world distance record for a projectile fired from a chemical gun.

Designed and manufactured assembly fixtures for assembly lines and welding departments in a 500,000 sq ft manufacturing facility, including fabrication with brakes, lasers, and milling machines. Programmed CNC mills, robotic brakes and welders. Served as department ProEngineer Administrator. Experience also encompassed capital expenditure justification, fixture and process training, project management, departmental ProIntralink administration, verification of engineering design (DFM) and feasibility of implementation.• Saved $2M per year by purchasing and implementing robotic welders and fixturing.• Coordinated and implemented fixturing database that allowed assembly fixturing visibility on work orders as a non-consumable item. This allowed fixturing maintenance schedules to be developed, and fixture existence to be more visible.• Implemented and designed assembly processes and fixtures, reducing Cost of Quality (COQ) by 15%.• Utilized capital expenditure justification, determining most financially solvent solution for a quality, assembly, or manufacturing problem.• Initiated fixture and process training of assembly personnel to better instruct them of cause (assembly) and effect (quality) of assembly procedures, allowing development of more efficient lines of communication that reduced time between process problem and resolution.

Directed all aspects of product design and build, on product lines that encompassed over 50% of daily plant output, in a 500,000 sq ft manufacturing facility. Created customer and sales driven design variations, retrofit packages for field service personnel. Engineering Change Requests, Field Service Requests, Service Parts Requests, Test Lab Requests, Quality Assurance requests.• Increased assembly line rates by over 100% over 2 years by addressing assembly problems related to design. • Created redesigns, improving case performance and efficiency, including coil sizing and development, and air curtain development. In some cases, a product was improved so substantially that it became a viable stand-alone product.• Redesigned refrigeration cases and yielded as much as 10% reduction in power consumption and 30% reduction in high product temperature, without adding manufacturing cost.

Held cradle to grave responsibility for all project aspects including: market and customer surveys, initial design, prototyping, redesign for cost reduction, design analysis and testing, sourcing vendors for production, customer relations, and product presentations.• Implemented and coordinated product area training regimen, allowing inside sales department to better sell new products, and technical department to troubleshoot product problems.• Designed award winning products (Gold Award) featured in New Product Design magazine.• Assisted in engineered several patented products and listed as the engineer on patent# 5,771,507 "extendable drain closure device".