Chart the course of innovation for cutting edge apparel production systems that enable fully automated manufacturing of garments at competitive costs anywhere in the world.

Provided consulting services for customers related to automated manufacturing of products. SME contributor to patent reviews.

Led Tegra's manufacturing innovation and automation efforts. Identified opportunities to modernize manufacturing methods and innovate through automation. Implemented projects with sub 1 year ROI, drove suppliers to innovate offerings, road mapped a path for future opportunities.

-Lead process development engineer of large format TDM optical bonding and touch sensor interconnect ACF processes-Worked closely with design engineering team to provide DFM feedback and assembly process tolerance analysisI oversaw startup and installation of the largest fully automated optical bonding production line in the world in our new factory. I led the process development and qualification phase of the project. I specify equipment changes required, and cooperated with the ME design team to implement a product design change needed to produce parts that met reliability and yield goals. After release to production, I assisted my manufacturing engineering partner with process adjustments to correct yield problems and reduce cycle time.I specified a fully automated system to apply ACF tape, a second, supporting, double-stick tape and place flex circuits on the touch sensor creating the touch sensor interconnect. While this is an established process for phone and tablets, Surface Hub is huge and needed a fully custom equipment solution. We started the project by leveraging materials and processes from the previous version Perceptive Pixel products with the intent to automate the process for higher production volumes. During the development phase, we found reliability problems that we root caused to the ACF material. We had to pivot and change ACF material during the middle of development. This resulted in a minor change to our existing ACF/flex placement machine but also required an entirely new thermal bonding machine. I led a team of engineers to qualify a new ACF material, add a new hotbar thermal process within an existing production line, and support incremental EV builds that used the new ACF material before we had the final production equipment installed.At Microsoft in Wilsonville, we truly succeeded and failed as a team. The cooperation among members of different "departments" was the best I've experienced and helped me grow as a lead engineer.

This was a contract position supporting the production of Invuity's surgical tools. I executed the design verification testing for a new product and wrote the requisite test documentation. I developed a validation plan for a new manufacturing process and drafted the required process validation documentation (IQ, OQ, PQ protocols). Life happened and a great opportunity to move to Portland fell into my lap and opened the next chapter for me professionally and personally.

- Supported automated production startup of Lighting connectors at 2 Japanese CM's- Identified automation opportunites in cable assembly lines and led automation feasibility projectsI supported the launch of the Lightning cable with the iPhone5. I spent an enormous amount of time working with two world class Japanese manufacturers, onsite in Japan, ensuring the lighting connector project was on track for product launch time. Both manufacturers were tasked with making the same component, both had fully automated high-speed production lines that had 7 assembly processes. And both manufacturers solved the assembly problem and automation different ways. I spent time working with each CM to understand their problems and determine if their automation or process was the root cause, or something else such as incoming material or product design.I also supported automation efforts on the cable assembly line (largely a bunch of manual processes). We didn't get to far with automated cable assembly but I led an effort to automate the first several steps (cut to length, strip jackets and insulation, and prep wire ends for solder to connector). I worked with a US automation supplier and a Swiss automation supplier in an effort to provide a fully automated solution to Apple's CM partner. Ultimately the automated solution wasn't cost effective (yet) compared to the existing manual labor solution. I dabbled in a few other products, traveling the world to review automation projects and assess whether it was adequate and on track for mass production.I spent a lot of time using Keynote to create clear, concise status summary slides. While that activity may sound mundane I believe the ability to create a single piece of communication that clearly states problems, risks and status, and can be digested in less than a minute is not a trivial task. I learned how to distill a huge project down to truly core issues and communicate that information quickly and clearly.

Chope Designs is my company for small engineering projects and pursuits outside of my “day” job. Recent projects include:- Design/Installation of an OSHA-compliant pneumatic-logic press control system.- Designed an automated alert system for use with autobelays in rock climbing gyms. Provided customer with a market ready product.

Developed and validated the manufacturing process for the production of a new lithium battery used in a pacemaker device.- Simplified process for sealing a polymer bag around a component while also improving process robustness and negating the need for a manual process monitor.- Wrote validation protocols, executed validation testing, wrote validation reports.- Developed machine vision inspection system for process using Cognex Vision Pro.Led the development of an automated inspection method for a new component used in a capacitor for an implantable cardiac defibrillator.- Spec'd vision system components.- Led work with outside vendor to develop custom software based around Cognex Vision Pro.- Partnered with internal team to develop specification for defects in parts.

Defined project schedules, administered budgets and oversaw engineering team in designing and fabricating complex automation equipment. Participated in customer meetings, including planning and concept design. Assessed and provided recommendations on new opportunities; developed detailed quotes. Teamed with vendors to expedite deliveries and specify component needs. Created set-up and operating instructions. Selected Contributions:- Earned reputation for excellent customer service in project management role, with personal requests from repeat customers such as 3M, Coloplast Medical, and Andersen Windows.- Personally managed 30+ projects that provided 15% of engineering sales in 2008.- Designed and managed the development of prototype packaging equipment that used a unique vertical-axis web handling system.- Designed a unique web handling system that allowed a web to be cut free while still allowing for a moving gripper to recapture the loose end of the web.- Extensive experience designing robotic end of arm tooling (EOAT) used with injection molding systems for overmolded parts.- Designed the mechanical fixtures and tooling needed for electrical testing of overmolded components for continuity and hipot requirements.- Developed pneumatically powered systems using toggle clamp mechanisms to produce hydraulic-like forces without the complexity of hydraulics.- Engineered a complex sequential clamping system controlled entirely by pneumatics that met OSHA safety requirements.

Planned and conducted experiments to identify new materials and processes to improve manufacture of rock-climbing handholds; applied advanced design of experiment (DOE) principles to analyze individual ingredients' effects in composite matrix. Managed process improvements for additional products and participated in new product / process development functions. Conducted client surveys; worked with vendors to acquire new product / material information. Prepared test samples and used tensile tester to measure strength. Wrote test instructions. Selected Contributions:- Achieved 30% strength increase in composite matrix, with 30% weight and 20% cost reduction.- Successfully managed requirements to bring new fiberglass handholds to market.- Instrumental in initiating use of fiberglass as climb wall / hold material and establishing production of large fiberglass simulated boulders by developing strong vendor relationship.- Designed and developed modular quick-install fiberglass climbing wall panels- Prototyped autobelay systems that used magnetic eddy current braking technology and band-brake friction brake, respectively. - Designed and prototyped fiberglass production techniques to dovetail with existing mold tooling, significantly limiting new costs associated with new manufacturing techniques.- Retained relationship with organization through consulting services.