David Macphee Email & Phone Number

I am currently seeking a position of manufacturing engineer, industrial engineer, quality, problem solving, supplier development, or project management- or a position possibly utilizing a combination of these areas.

Existing Process & Continuous Improvement (2005 - 2009)Lead engineer for production support of existing evaporator manufacturing process for flame braze pipe attachment, leak test tooling, pipe end point gaging. Conducted Measurement System Analysis studies for major process measurements. Prepared for and supported ISO-9000 audits.Reduced noise generated machines from 85 dba to less than 80 dba through alterations. Led efforts to have 17 electric torque guns meet customer specifications for assembly.Led implementation of error-proofing to handle rejected parts in a separate process stream.Showed statistical conformance to specification supported by reduction of variation and re-targeting tooling process means for 11 evaporator models for CMM pipe end point capability. Led conversion of tooling for a model being reduced to a model increasing in volumes, saving $25,000 and 2 months time. Coordinated design, parts build, and conversion of in-production test fittings to reduce false test rejects by 53% over a 1 year period saving $27,000.Led the manufacturing plan for 10-41 year old service models to be built in the existing processes.Validated an automatic measurement system using MSA methodology to measure heat exchanger size, while conducting an automatic leak test process; saved $36,000 per year.Led process improvement to detect heat exchangers missing an internal part from being passed on to the customer, resulting in zero defects passed on from 18 defects in a 1 year period.

Implement New Models (1999 - 2004)Member of team that implemented 9 new model evaporators. Worked on pipe design, dimensioning, supplier development of pipes, measurement, tooling to attach pipes, gages for final assembled product, and CMM inspection. Oversaw project spending, forecasting, and meeting budget.Developed the assembly fixtures & process for a block TXV onto pipe end points with electric torque guns used for assembly conformance and electronic error-proofing.Achieved a 38% reduction in heat exchanger dimensional end point variation by converting from weld process fixturing to a new flame braze process with a new approach of fixture design.Played an integral role on a Lean Project team that resulted in a 48% labor reduction for flame brazing versus an older welding process and with an average of 3% quality improvement over 6 manufacturing cells, the team saved $864,000 annually.Close leadership and direction to coordinate continuous improvements to new processes with skilled trades for the most minimal impact to the manufacturing operations.

Design for Manufacturability and cost estimating.Manufacturing engineer for a 10-member product design team. Drove design for manufacturability to the earliest design levels possible to reduce cost estimates, project budgets and manufacturing damage. Supported and led team though samples at the cobbled tool and earliest of prototype samples to demonstrate product design and function to the customer to "win the business".Achieved significant reductions in project budgets (greater than 30%), product damage in manufacturing (greater than 70 % improvement), and customer complaints (reduced from 200 to less than 50 per year).Supported Europe and Mexico operations for product manufacturability and tooling design reviews. Including travel for extended on-site support visits.

Implement Domestic & Europe New Models; Performed estimating and facility installation for domestic models and support/ mentoring for Donchery, France operations.Successfully led team of 4 engineers in implementing a challenging TXV conversion on evaporators to the existing GM-N/L car platform with flawless conversion between old and new designs; promoted to Sr. Manufacturing Project Engineer.Supported flawless transfer of 6 heat exchangers models to France operations for European customers with 7 trips.

Handled estimating, prototypes, early pilot builds, low volume & high volume process implementation, and achieving project budget for cost & labor. Challenged product specs to achieve 70% reduction in false test rejects.