Melissa Workman Email & Phone Number

Norwalk, Connecticut, Us

Worked with a team to define, test, and implement a field rework process. Developed a financial model to predict the impact of the rework. Failure rates used in the model were obtained from a Reliasoft Weibull analysis. Net return estimated at $3M. Presented team findings to senior management at regular intervals. Tracked team spending, ensuring the project stayed within budget. Developed a schedule that accounted for executing the test plan, identify and qualifying a supply chain, creating training material, and coordinating release to the field. Led team meetings to develop a DFMEA and PFMEA used to improve the design of parts and the process to reduce the risk of introducing new failure modes in the field. Led a subset of the team in parallel to develop an in-factory rework process that allowed the use of material which would have otherwise been scrapped, without impacting product quality and achieving $250k in cost avoidance.Managed continuous cost reduction and productivity improvement projects. Tracked $2M in production productivity cost down projects ensuring targets were met. Negotiated quarterly with our production supplier for revised cost model pricing. Executed a flex cable plating change leading to savings worth $400k annually.

Norwalk, Connecticut, Us

Assisted with the process transfer from R&D to manufacturing for two products simultaneously and supported the launch of the first production size, continuous feed, solid ink printing press. Coordinated the transfer of equipment and the build process from the US to Malaysia. Maintained build and revision control and supported the transition of assembly and test processes to our manufacturing facilities. Managed capital planning and scheduling. Collaborated with R&D to define the process flow and equipment requirements. Served as the liaison between the main program and the printhead manufacturing groups to ensure collaboration on mutual objectives. Arranged logistics and ensured maintained quality of supply chain deliverables to support the printhead build plan. Owned and maintained the printhead BOM.

Norwalk, Connecticut, Us

Integral contributor to the successful launch of the first tabloid size solid ink printer. Designed and assembled manufacturing and test equipment for the printhead and reservoir. Established, documented, and maintained printhead assembly and test processes. Provided feedback to R&D regarding Design for Assembly by using poka-yoke principles, reducing quantities and types of fasteners, and reducing orientations and torque settings. Participated in new product design meetings and reviews to ensure that part designs were robust and manufacturable. Set up and maintained the capacity modeling for a new product line ensuring all appropriate equipment was installed to support the production ramp and launch. Supported management in capital planning, forecasting, reconciliation, and inventorying of assets to ensure money spent on the new manufacturing line was properly accounted for. Traveled to Malaysia and the Netherlands multiple times to qualify equipment, set up manufacturing lines, and provide training ensuring a successful product launch. Documented all processes with clear, concise, and illustrated instructions. Updated drawings, part numbers and the BOM for the printhead ensuring the correct version of parts were ordered for each build prior to and following the product launch.

Norwalk, Connecticut, Us

Supported the launch of a new letter size printer by designing manufacturing and test equipment and developed assembly procedures. Transferred equipment and processes to the manufacturing site in Malaysia. Achieved yield improvements and reduced the manufacturing cost through the use of DFLSS and Shainin problem-solving methodologies.

Houston, Texas, Us

Set up and implemented methodology tests in development of a new wafer singulation process. Successfully developed a method for packaging and singulating a wafer that created a lid for each individual package allowing micro devices (MEMS) to be protected and sealed under the lid. The new process received two patents, patent numbers 7,026,189 and 7,196,410.

Developed instructional web-based dynamic models using ADAMS and Dreamweaver software for Wiley publishing to accompany the fifth and subsequent editions of Meriam and Kraige’s Engineering Mechanics: Statics and Engineering Mechanics: Dynamics textbooks.