• Performed glass utilization study to increase cutting yields by 5% and saved $250,000 annually.• Worked on vendor, operator, and equipment issues to raise yields on one of the highest volume products from 60% to 85% for an annual savings of about $1,000,000.• Developed and implemented ACF bonding process for flexible circuits on glass.• Utilized AutoCad Mechanical and Inventor for process design, product design, and line layouts.• Designed touchscreen linearity patterns using Electro simulation software.

Recruited to create a world class process for an electrochromic mirror manufacturing operation.• Served as Manufacturing Engineering Manager of an 18-member team of manufacturing engineers, process technicians and maintenance technicians for two years.• Managed $2.5 million capital project for the development of processes to build electrochromic outside mirrors that led to the launch of a new product a year ahead of schedule.• Designed and managed $8 million capital project to successfully launch electrochromic outside mirror production in Holland, Michigan. Utilized Microsoft Project to track progress and used PowerPoint, Word, and Excel to present results. Project included cleanroom facilities.• Developed laser etching process for marking outside mirrors and programmed new products using dxf files created with LaserCad, Mastercam, and AutoCAD LT.• Involved in troubleshooting of equipment including PLC controls, mechanical, pneumatics, vision systems, and process variables.• Mentored new engineers to transfer product and process experience and improve their productivity.• Glass experience included purchasing, inspecting, handling, cutting, bending, annealing, washing, vacuum coating, laser etching, and assembly work.• Adhesive experience included acrylics, epoxies, silicones, hot melt, and others cured by heat, moisture, reactivity, light, and UV exposure. Developed and programmed 3-axis dispensing equipment.• Utilized AutoCAD LT for line layouts, equipment design, tooling design, and some product design.• Participated in APQP process that included writing FMEA’s, process flow charts, machine specifications, equipment validations, control charts, and run-at-rate trials.• Worked with design teams to answer Design-for-Manufacturability questions and was the voice of manufacturing at design reviews.

Managed improvement and development projects for automotive overhead systems manufacturing.• Researched and implemented advanced manufacturing techniques for overhead systems. This included the forming of the fiberglass mat into a headliner and attachments to the processed mat.• Participated in 8 different Kaizen events that improved quality, cycle time, and efficiency.• Received patent on new headliner attachment device that is now in production use.• Assisted in the development of new materials to support the Head Injury Criterion (HIC) testing.

Recruited to take the electrochromic mirror out of laboratory development and into commercial availability. Responsible for designing, building, and equipping the production facilities.• Authored all operator work instructions and developed the preventive maintenance program.• Chaired the continuous improvement team for 4 years, increasing yields from 50% to 92%.• Instrumental in reducing wave soldering defects from 4000 ppm to 400 ppm in 6 months.• Set up and facilitated the first ever electrochromic outside mirror assembly operation which included cleanroom facilities.