Sean Cavanagh Email & Phone Number

United States

Available on a part-time basis to support individuals or organizations with product development, design for manufacturability, or quality system needs.

Born in my garage as a side hobby for exploring the art of welding, Flying Iron has continued to be an inner creative itch that I just can't shake. Work is focus on hand fabricated steel+wood furniture and home accessories.See more at www.flying-iron.com

Denver, CO

• After nearly 10 years with Boa, it came time to pass the baton and explore new opportunities. This final role in the organization was formed to allow me to help transition my scope of responsibility to some new hires.
• Oversight to the completion of a new small-volume short-lead-time production center inside our contract manufacturer
• Training of new dedicated resources for Document Control, Quality Engineering, and Quality Management
• Transition of management relationship with Boa’s China office and contract manufacturer

Denver, CO

• This recent transition has occurred as Boa’s product team has grown to more than 35 people and total company size has grown to more than 150. Thusfar, this role has focused on the following initiatives to help the.
• Implementation of Solidworks Enterprise Product Data Management system (EPDM)
• Formalized quality system to improve the awareness and clarity of the relationships between established processes, procedures, and control documentation
• Formation of additional management layer to focus improvements in the areas of Testing and Sustaining
• Large scale project with Boa’s primary contract manufacturer to revamp injection molding capability and capacity

Denver, CO

• While maintaining most of my responsibilities as a Project Engineer, I took over responsibility for all Asia manufacturing activities. During this time, significant advancements were made to improve the product quality.
• Revamp of product spec documentation to more efficiently and effectively hand designs off to our contract manufacturer
• Development of structured production pilot run process to ensure products entered production with a balanced assembly line structure and proven quality control method
• Expansion of product quality team with the addition of a senior Manufacturing/Quality Engineer and three Laboratory Engineers
• Development of an Asia based manufacturing/quality support team based in Shezhen, China to support production start-up and production audit programs; team included a general manager, two Quality Engineers, and one.
• Implementation of mold quality and life standards to create longer lasting molds

Denver, CO

• Following the addition of five new product development team members and the merging of engineering with product development, I became Boa’s first project engineer and remained the only project engineer for four years.
• Oversaw and managed the engineering activities for nearly twenty projects at a given time
• Owned and managed projects through mold development and mass production qualification
• Hired two additional Engineering Technicians

Denver, CO

• Following a 6month internship in 2006, I joined Boa as the 13th employee in the company and the second engineer in its three-person product development group. Within this role, I operated as a general support engineer.
• Sustaining - developed and implemented design changes/improvements for existing products
• Design Engineering – performed FEA on new designs and developed CAD for internal mechanical components
• Quality – created quality control documentation and managed part qualification activities
• Field Test System Creation – Managed one Field Test Coordinator and developed system for getting field test validation data from nearly 100 active field testers
• Lab Creation – hired first Engineering Technician responsible for supporting part inspection and performance testing