Gerard Parcella Email & Phone Number

Tewksbury, Ma, Us

Managing engineers and assemblers responsible for ownership of process development, manufacture, testing and delivery of 3D Printers for the rapid prototyping marketplace. Responsible for manpower planning, 6S audits, continuous Lean improvement, yield performance, cost reduction, capitol planning and Manufacturability/ NPI collaboration.

Greater Boston Area

Results-oriented leader focused on improved overall execution and enhanced financial performance for organizations in a variety of industries.Strategic consulting services aimed at continuous improvement of manufacturing operations.

Managed 16 engineers responsible for the production support to printed circuit board, hybrid, and mechanical assembly areas. Accountable for process development, yield performance, labor improvement, cost reduction, capacity planning, and new product design for manufacturing (DFM) efforts for sensor technology defense products.• Successfully managed new product DFM efforts to impact new designs for cost, quality and performance, resulting in accelerated maturity levels for initial production builds.• Directed the specifications, purchased equipment, and developed processes for a $12 million fully automated PWA line including the renovation of a 50,000 square foot manufacturing facility.• Completed Green Belt training and certification, applying knowledge to implement Six Sigma and Lean principles which reduced errors and eliminated waste in the manufacturing processes.• Achieved year-over-year labor cost improvements averaging $1 million annually for over five years.• Conceptualized and implemented software tools to get instant feedback and trigger action plans to resolve problem areas, improving and maintaining process yields to greater than 98%.

Directed new product introduction efforts including process set up, manufacturing procedures, fixture design, layout, engineering change activity, and DFM activity. Managed 18 employees in manufacturing engineering floor support, engineering documentation control, custom tool design and production planning for automated dispensing equipment used in the semi-conductor and PCB industry.• Project managed outsourcing effort for a $5 million precision pump and dispensing equipment operation, completed on time and within budget.• Led close down of operations including negotiating terms of sale, moving physical and human assets, establishing target pricing, and transitioning processes and documentation to new suppliers.• Engaged four teams covering six product lines to implement Lean manufacturing including plant layout, re-sequencing operations, and establishing self-measured metrics to incorporate cell ownership.• Improved the engineering change process, resulting in more accurate engineering documentation and software revisions.

Originated program, developed goals, and recruited seven-person team to implement a company-wide cost-reduction program for the design and redesign of semi-conductor products. • Collaborated with five engineering groups to successfully establish format for the cost reduction initiative including supplier interface, project justification, modeling and testing.• Drove new product cost-reduction initiative that reduced machine cost by 35% and exceeded goals of $3 million to $7 million savings annually.• Achieved cumulative annualized savings of $40 million on more than 250 projects producing machines comprised of 12,000 parts manufactured to clean room standards.

Managed 40 employees in three departments producing night vision optical products totaling $25 million in annual sales. Managed a $2 million facilities budget to maintain and renovate half of the 150,000 square foot facility.• Built a highly focused, goal-oriented production team comprised of a two-shift mechanical and optical assembly operation, improving gross margin from 11% to 18% in four years.• Ensured compliance with MIL-2000 and ISO-9000 standards.• Engaged a team to implement new production scheduling and manpower planning process, subsequently exceeding monthly revenue goals for 18 consecutive months.• Established a perfect on-time delivery record, coupled with zero customer product returns to become the #1 worldwide supplier of night driver’s viewers.• Achieved cost targets and reduced rework from 12% to 2% by converting the factory to Just-In-Time (JIT), reorganizing all bill-of-materials and performing a complete relayout and upgrade of the entire production process resulting in a streamlined factory.• Led redesign of six key manufacturing engineering processes including DFM and documentation which reduced new product introduction time by 50%.

Managed 12 engineers responsible for all aspects of printed circuit assembly from the design/producibility phase through pilot production and into off load to 3 manufacturing plants.• Directed Surface Mount Technology process introduction including $1 million equipment selection, process set-up, and pilot production management resulting in the successful SMT automated process implementation with-in budget and on schedule.• Managed the production of SMT product, including SMT lab to maintain material specification control, initiated CAD controlled vendor/process data, documented process and inspection guidelines resulting in 99.5% quality yield and build costs that were 50% less than outside.• Developed new product introduction process that established "Design for Producibility" guidelines for materials, footprints and technology for the assembly of double-sided SMT mixed technology printed modules and panelized products with a turnaround time of 2 days.• Coordinated off load strategy consisting of preparation of N/C programs, tooling, process documentation, equipment procedures, cost standards, repair capability, and operator training for the successful transition of product and processes to off-shore facilities.

M.S., Engineering Management

B. S., Industrial Engineering

Certified Six Sigma Dmaic Lean Green Belt

ADDITIONAL TRAINING: Toyota Production System (TPS) for Executives Good Manufacturing Practices (GMP) Design for Manufacturing & Assembly.