Melody Muehlbauer Email and Phone Number

*Leads weekly technical meetings that facilitate technical discussions and decisions, drive task management of team members, and provide path for escalation of technical issues on the project. *Initiated, organized, and led Kaizen Event that delivered high impact solutions to manufacturing metric deficiencies identified during Pre-DV builds, resulting in a Pilot Line bottleneck process cycle time reduction of over 50% and COGS reduction of 30%.*Led technical discussions to develop strategy for key deliverables including PFMEA, Process Design, PC, Process Validation IQ/EQ, and line installation and qualification in Costa Rica clean room. *Created and maintain MS Project schedule of industrialization activities*Determined process capability via DOEs and performed feasibility, manufacturability, and make vs buy analysis of automated vs. manual tube flaring process, contributing to a MoH reduction of 30%. *Designed, prototyped, tested, and implemented:**New fixture system that introduces microcable assembly with consistent tension to device extrusions on Pilot Line that improves product quality and operator efficiency, resulting in a process cycle time reduction of 70% and footprint reduction of 50%. **New travel fixture system on Pilot Line that safely houses the product at every manufacturing process to reduce handling failures while also streamlining assembly steps, resulting in a touch time reduction of approximately 65%. **Design feature addition to BoM component by collaborating with vendor to determine manufacturability at volume and reduce in-house process cycle time and Cost of Non-Quality, resulting in an 88% cycle time reduction for that specific process step. *Created and implemented Pilot Line floor layout, contributing to a throughput increase of three times the average part completion per day, by leveraging historical cycle time data, demand quantities, takt time calculations, and level-loading lean principles to generate optimal flow proposal.

Implemented Standard Work, Visual Factory (6s), and revised Standard Work Instructions to improve process efficiency and on-time delivery as a member of a Kaizen Event for an assembly manufacturing cell. Designed and constructed material kits and a cart to improve material traceability and create a pull system. Designed and implemented custom equipment shadow board mounts to reduce waste of motion and establish a workplace standard for tool management.

- Authored compliant shipping, handling, and storage procedures to conform with rigorous customer requirements of specialized products. Customer approved first iteration of new revision. Trained production staff on new procedures and verified process compliance. - Performed and analyzed process observation of product line to determine how to productionize and integrate a new product into the current process. - Acted as liaison between vendors, lab, and customer to coordinate a material compatibility test suite. Researched quality, cost-effective testing and procurement options.- Executed in-house pre-qualification testing with mockup equipment. Performed research and data analysis to complete test suite to customer standards. Developed method, instructions, and documentation package for assembly of a full-scale mockup at an international customer facility successfully constructed and tested in Q1 2021.

- Programmed in Python and developed a statistical process control tool (SPC) in Tableau to improve yield by reducing dimensional variation. - Collaborated with a team of engineers to design a new load frame machine based on customer requirements. Modeled in SolidWorks and mathematically validated the hydraulic, pneumatic, and load application systems, which were designed to improve measurement reliability and repeatability.

- Supported the design and development of a minimally invasive medical device. Implemented and tested product design changes based on Finite Element Analysis, frequency spectrum results, and SolidWorks modeling. - Designed test fixtures, created corresponding engineering drawings, and assembled fixtures for use in production. Improved repeatability of the assembly.- Authored manufacturing assembly instructions and developed protocols for load testing.

- Researched the biomechanics of rowing for use in the medical field and for commercial products for athletes- Collected full-body human kinematic and dynamic data using VICON Motion Capture System- Analyzed joint angles, forces and power relationships through post processing in MATLAB

- Performed cost accounting tasks on client expense reports.- Sorted case costs and created invoices for billing- Filed exhibits, appeals and other legal documents with the court of opposing counsel; prepared pleadings- Managed communications among clients, lawyers and outside entities- Organized and maintained documents in paper or electronic filing systems, often using case management software