Providing consulting and project management expertise to clients- in the design of new products to make them manufacturable with the best combination of state-of-the art processes at a price point that invites customers- to reduce production costs through a combination of waste elimination and up to date manufacturing processes- by organizing quality functions through documentation and control of critical procedures, designing systems that prepare them for ISO 9001:2008 certification- to manage multi-million dollar engineering projects through the design, fabrication, and implementation phases

Led manufacturing development efforts for microchannel chemical reactors, including process development, cost estimating, material characterization and commercial production scale-up. Developed processes in photochemical machining and stamping of fine features, plating, diffusion bonding, machining, and welding.• Supervised and coached five direct reports developing manufacturing processes, building prototypes in support of design engineering. • Managed $2.5MM manufacturing process scale-up effort for super-alloy chemical reactors including build of custom equipment and proof of concept through prototype build.• Designed and built custom, semi-automated hardware, for measuring gas flow rates in microchannel devices.• Redesigned manufacturing operations and supervised equipment moves from secondary facility. • Supervised design-of-experiments and process development for diffusion bonding superalloys.• Managed development of automated machines for building hi-tech chemical reactors using laser welding.• Established company quality system: implemented document software, wrote key ISO-9001 documentation, led internal audits, conducted management reviews, initiated continuous improvement program.• Defined machine requirements, wrote purchase specifications, supervised runoff, and coordinated shipping, delivery and installation of metal stamping presses.• Managed selection and installation of coordinate measurement system with vision capabilities in support of product and process development.• Developed key partnerships with suppliers of stamping, diffusion bonding, plating, photo-chemical machining, and CNC machining. Designed supply chain to produce chemical reactors from start to finish.• Conducted Process Failure Mode Effects Analyses (PFMEA) for new process development.• Monitored technology programs at universities, corporate technical centers, and trade organizations.

Directed activities of 10-person staff responsible for all engineering activities at plant, including capital equipment projects, product costing, process and tooling design, manufacturing support, and new process development.• Reduced scrap and cell downtime by 16% and improved productivity by 98% through specification, selection, purchase, design review, certification, and installation of rapid-heating gas furnace• Designed new fixturing and automated part ejection system for in-field machine retrofit. Created drawings, selected vendors, and served as project manager, completing project on time and within budget.• Managed flashess forging program, reducing raw material need, improving tolerances and finish quality, and implementing production changes. Converted second plant to nearly 50% flashless technology in 5 years.• Increased sales 17%, reduced scrap and increased part quality via development of new shaft forming process. • Replaced trial-and-error design method with finite-element-method process simulation software. Improved design efficiency and increased tool life.• Researched new materials, conducted in-plant trials, and changed material standard to improve tool life 293%. • Wrote custom software solutions for controlling engineering-critical data, including complete material specifications system, metallurgical certification database, production control, and document control. • Decreased design time by 49% by implementing new 3D CAD system and writing parametric design program. • Managed precision gear-forging program. Wrote custom CAD/CAM software, developed tooling designs, supervised production runs, collaborated with customers to improve quality.• Implemented new forging technology to improve product quality and increase productivity at divisional level. Reduced setup times and raw material by 37% and 15% respectively.• Consolidated programs and improved efficiency on semi-automated axle friction-welding line.

Directed activities of seven engineers and scientists conducting contract research to develop computer-based tools for design and analysis of manufacturing processes. Led proposal effort for $28MM DOD project to establish a gear manufacturing research center, including marketing trips to major German, French and Swiss machine tool builders. Speaker at technical conferences and large, multi-client group program sessions.