Dan Esterly Email & Phone Number

West Chester, Pa, Us

West Chester, Pa, Us

King Of Prussia, Pa, Us

- Recertified company to ISO 9001 and 14001 including expansion of quality system to include newly acquired manufacturing facilities.- Managing global regulatory requirements for materials provided to customers.- Approval and Monitoring of suppliers for fitness of purpose.- Investigate and report on field failures, customer complaints, and internal process failures.- Report on company metrics and lead monthly management review meetings.- Develop and maintain Quality Management System and relevant documentation.- Investigation and disposition of non-conforming product using Five Why, 8D, Fishbone Diagrams to determine root cause and corrective action.

Us

• Achieved ISO 9001 certification for National Foam. First time the company has been ISO certified.• Manage projects for customer deliverables and internal process improvements.• Review customer requirements for feasibility and participate and design reviews with engineering and suppliers.• Manage suppliers for product quality, project deliverables, and on time delivery.• Initiate, review, and implement design changes to address issues with manufacturing and product performance.• Investigate and report on field failures, customer complaints, and internal process failures.• Managing third party listings at Underwriters Laboratories and Factory Mutual.• Create test specifications and procedures to validate product quality.• Report on product quality and test results.

Trelleborg, Sweden, Se

• I provided recommendations and training on high performance polymer seals and bearings both internally to Trelleborg and externally to customers. Internal to Trelleborg my customers were worldwide. Externally I support customers in the Northeast United States from Virginia to Maine.• Working with our inside sales force I helped provide our customers with timely quotations and product deliveries• With help from outside Sales Engineers I made sure the customer received the most suitable product to fit their needs, even if it meant going to a competitor.• Specialized in sales of high performance polymer based seals for demanding applications.• Provided training on seal performance, material capabilities, hardware design, seal installation, and failure analysis.• To help our sales force and engineers work with our ever expanding line of products and manufacturing capabilities I developed tools to make locating information faster and inter-company communication easier.Project Examples:http://www.flowcontrolnetwork.com/articles/high-end-seals-have-bigdog-robot-up-and-running

Van Buren Township, Mi, Us

• Managed projects for the product development of multiple driveline components on the successful launch of the 2005 Lincoln Navigator.• Designed, tested and launched driveline components based on customer needs and manufacturing feasibility for 2 light truck and SUV programs. • Designed prototype driveshafts, sourced components, organized prototype fabrication, and provided on-time delivery to customers for vehicle development builds. • Led in-house initiatives and managed projects to provide solutions for industry needs and requirements addressing vehicle driveline noise/vibration/harshness (NVH) issues. • Design and release new components to address customer requirements, and improve quality and productivity in manufacturing. • Design and redesign products to assist with assembly on the production line, improving productivity and reducing mishandled and damaged components.• Use Six Sigma to improve component designs and manufacturing processes. • Identify, investigate, and implement cost savings and quality improvements based on competitive benchmarking and warranty analysis. • Generated cost savings of over $3 million per year by redesigning, resourcing, and outsourcing components and assemblies.• “Leading the Way” Recognition for NVH quality improvements on the Ford F150 vehicle line.• “Leading the Way” Recognition for exceeding material cost reduction goals. • “Certificate of Quality Excellence” for design and process improvements on the Ford F150 vehicle line.

• Manufactured highly crystalline and oriented Poly(vinylidene fluoride) polymer films as a candidate piezo-electric polymer for semi-active vibration damping applications. • Developed unique test methods for measuring the vibration absorption and dissipation characteristics of polymer films by applying voltage across the films while using standard material analysis equipment. • Conducted proof-of-concept testing of utilizing magneto-rheological fluids for the deactivation of mechanical systems; supported by the US Navy.• Demonstrated relationships between elastic modulus and applied voltage in piezo-electric polymer films.Publication: DM Esterly, and BJ Love, Phase Transformations of Poly(vinylidene fluoride) by Ball Milling, J Polym Sci, Poly Phys Ed, 42(1), 91-97 (2004).

United States, South Carolina, Us

• Conducted quality control of the plating processes of electronic components, including validation prior to customer use.• Reduced scrap by over 50% through operator education and the implementation of strict preventative maintenance schedules.• Troubleshoot and repair equipment on the factory floor, and validate new equipment when necessary.• Investigated and implemented new equipment and processes to improve overall efficiency of the plating operation.

Ms, Material Science And Engineering

Bs, Mechanical Engineering