Dan Carabell Email & Phone Number

Ann Arbor, Michigan, United States

8+ years of materials engineering and operations management experience using lean six sigma manufacturing principles. Specializes in sand casting processing and heat treatment of lightweight metals, such as aluminum and magnesium. Experienced in failure analysis, metallurgy, materials processing, and material characterization techniques including optical microscopy, scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), Fourier transform infrared spectroscopy (FTIR), and X-ray diffraction (XRD).Specialized in improving lightweight metal casting processing including tungsten inert gas (TIG) plug welding, heat treatment fixturing and processing, hot isostatic pressing (HIP), laser and white light dimensional scanning as well as 3D sand printing technology.Areas of Specialization:Sand Casting Lightweight Metals (Aluminum and Magnesium)Heat Treatment of Lightweight MetalsMetallurgyMaterials Processing and CharacterizationFailure AnalysisLean Six Sigma Manufacturing

Minneapolis, Minnesota, United States

Greater Minneapolis-St. Paul Area

-Supervised and mentored a team of 7 product engineers to effectively communicate with customers as well as maintain legacy component portfolios-Lead cross functional teams to drive scrap reduction down 44% through six sigma methodologies in a 12 month period

Greater Minneapolis-St. Paul Area

-Managed a diverse portfolio of castings, as the sole owner, while being responsible for process sustainability, continuous improvement, and direct customer communication-Achieved FAI approval for over $3M of tooling for new product introduction leading to LTA contracts for future sales-Lead CI team in charge of reducing scrap rate of high impact products. Reduced scrap rate of one product from 30% to 6% in 3 months, saving over $350K in projected lost sales-Mentored a team of interns in the development and execution of summer projects as well as determined the ROI impact on the business

Troy, Mi

-Conducted competitive analysis of prospective products and companies that may be implemented into Magna. -Investigated intellectual property and novel technology to advance the Multi Material Lightweight Vehicle Project.-Produced systematic and component diagrams of various technologies for gate reviews and reports using PowerPoint.

Ann Arbor, Michigan

-Assisted and provided technical support to engineering consultants during site and product inspections.-Performed metallographic analysis to determine location of crack initiation and failure mode of the several products.-Rewired hydraulic motor and control panel of an MTS material tensile testing machine.Built and designed testing fixtures to assist in evaluating consumer product flaws during surrogate testing.

Livonia, Michigan

-Composed an assortment of lab reports documenting TRW Material Lab investigations.-Supported TRW Foundation Brakes, Actuation, and Slip Control engineering groups by investigating material failures.-Executed metallographic analysis to determine microstructure, extent of porosity, and hardness of various metals.-Performed polymer testing including heat age resistance, hardness, tensile and tear testing to TRW specifications.

Sterling Heights, Mi

-Fabricated and built motor compartment mainline for General Motors.-Utilized PLCs using RS Logix 5000 and Factory Talk to simulate General Motors assembly line.-Designed, modeled, and simulated stress tests for a toggle lock assembly using Solid Works software. -Certified and installed end effectors on Fanuc robots.

B.S.E., Materials Science And Engineering, Graduate

Activities and Societies: Co-Founder and Vice President of Michigan Longboarding Club, Winter 2012; Member of the Michigan Materials.

Master Of Science (M.S.), Materials Science And Engineering, Graduate

Activities and Societies: Member of the Averback-Bellon Research GroupGPA: 3.88/4.0 Relevant Coursework: Point and Line Defects, Mat..

High School/Secondary Diplomas And Certificates

Activities and Societies: Varsity Basketball, Soccer, and Track, Member of National Honors SocietyClass of 2011 Salutatorian