Stephen Macintyre Email & Phone Number

Montreal, Qc, Ca

Montreal, Quebec, Canada

Austin, Texas Area

Flextronics is one of the largest contract EMS suppliers in the world, with customers in every segment of the electronics industry. At the factory in Austin, I am responsible for building the PCBA’s used in the Mac Pro workstation for Apple (www.apple.com/mac-pro), including:- Process engineering support through multiple development build cycles, ramp-up, launch, and sustaining production, including coordinating support activities for other engineers and technicians for a 24x7, high volume operation.- Supporting all aspects of building printed circuit assemblies, including screen printers, solder paste inspection, placement, reflow, automated optical inspection, X-ray inspection, through-hole insertion, selective solder, adhesive dispensing, mechanical assembly, routing, and conventional and hot air repair.- Development and maintenance of all process work instructions for the PCBA operation, including managing ECO signoffs using the Agile document management system.- Extensive defect analysis to drive process improvements, resulting in a current rolled through yield of greater than 99%.- Design and sourcing of tooling including stencils, process carriers, and support fixtures.

Plano, Texas

As the primary engineer in the CORE lab in Plano, TX, a prototype/NPI line supporting the industrial and medical segments among others, my accomplishments and duties included:- New product introduction for dozens of products, including extensive customer interaction, new product evaluation, and design for manufacturing (DFM) analysis.- Development of a Manufacturing Process Instruction template, greatly improving the time taken to setup a new product.- Supporting all aspects of building printed circuit assemblies, including screen printers, placement, reflow, automated optical inspection, X-ray inspection, wave solder, wash, conformal coating, mechanical assembly, and repair, using both aqueous and no-clean, leaded and RoHS chemistries.

As the process engineering manager for the FlexMedical facility in Milpitas, CA, I was responsible for:- Managing the process engineering department, including product engineers, process engineers, process technicians, programmers, and maintenance technicians- Coordinating an end-to-end quality improvement for a high-volume product, resulting in a 90% reduction in customer returns.- Multiple process validations, including installation qualification (IQ), operational qualification (OQ), and performance qualification (PQ).- Installation, setup, and training of a new Panasonic CM602 placement line.- Assisting with product transfers to China, including onsite support.

OMNEX Control Systems, a subsidiary of Cooper Bussmann, is an OEM manufacturer of RF remote control and industrial wireless systems based in Port Coquitlam, BC. As the Manufacturing Engineering Manager, I was responsible for:- Managing the manufacturing engineering department, including manufacturing, process, and test engineers and technicians.- Development and sourcing of new processes and equipment, including a MyData placement cell, Vitronics reflow oven, and solder paste qualification.- Development and implementation of multiple standards, including stencil design, DFM, manufacturing work instructions, BOM standardization, and MyData programming.- Site coordinator of Cooper’s MVP (Lean Six Sigma) program, and trained as an MVP Apprentice (greenbelt).- Participated and led multiple Kaizen events, including facility layout, productivity, system integration and setup reductions.- Supporting all aspects of SMT assembly.

Aguascalientes Area, Mexico

Based in Plano, TX but primarily supporting the Aguascalientes, Mexico facility, my accomplishments and duties included:- Green-field setup and installation of a PCBA manufacturing operation within an existing final assembly/integration factory. In this role, I had a broad scope of responsibilities, including equipment evaluation, selection and sourcing; staffing of engineers, technicians, and supervisors; factory layout; and process definition including chemicals, tooling, and software. This project came in on time, building our first prototype within three months and starting full production within six months. I was also able finish the initial line setup 10% under budget while at the same time expanding the scope of the project to include processes not previously considered, such as automated through-hole insertion, PCB routing, and conformal coating.- Managing the PCBA engineering department, including process, product, document control, test, and maintenance engineers as well as technicians and production supervisors.- New product introduction, including extensive customer interaction, new product evaluation, and DFM.- Capacity analysis including strategic allocation of capital resources.Supporting all aspects of SMT assembly.- Process and product capability analysis using DOE methods and tools such as Cpk analysis and gage R&R.- Qualification of RoHS-compliant SMT and wave solder processes.

Watertown, Sd

OEM is a high-mix, low-to-medium volume electronics contract manufacturer, specializing in medical devices for a large number of customers in the Midwest and around the country. As senior process engineer and engineering supervisor, my job duties and accomplishments included:- Leading the process engineering department, including other process engineers, engineering technicians, maintenance technicians, and machine programmers.- Supporting all aspects of SMT assembly.- Development and evaluation of RoHS-compliant SMT and wave solder processes.- Development and qualification of new manufacturing processes, including the installation and setup of Fuji CP643 high-speed placement machines, Photon Dynamics automated optical inspection (AOI) systems and the qualification of both no-clean and aqueous solder pastes and wave solder fluxes.- Machine programming of Fuji placement equipment using GCPlace and Fuji Flexa software.- Safety committee chairman, including OSHA trainer certification (now lapsed).- Training and mentoring at all levels, from operators through to other process engineers.

SMTC is a tier two contract manufacturer of electronic circuit board assemblies for various customers around the world. As a process engineer in Toronto and Austin, I was responsible for:- Supporting all aspects of building printed circuit assemblies, including extensive experience programming, optimizing, and balancing Panasonic placement machines and lines.- DFM support, including drafting the corporate DFM specification and on-site support for a multi-billion dollar customer.- Process development and engineering support for the new product introduction (NPI) team, supporting quick-turn and prototype builds for a wide range of products of varying complexity.- Developing and qualifying new processes, including no-clean chemistry, paste-in-hole soldering, press-fit connectors, and double-pass wave soldering.- Cpk analysis of process capabilities including screen-printing, machine placement, and reflow soldering.- Failure analysis of a wide range of defects and problems, including DOE.- Development and maintenance of a corporate-wide capacity planning model.- Sourcing and overseeing the installation and upgrade of new equipment and software.- Training operators, inspectors, and other support staff on various aspects of circuit board assembly through formal training classes and on-the-job training.

As a participant in the Industrial Internship Program, a 16-month work contract for pre-graduate engineering students, I was responsible for:- Plant-wide implementation, upgrade, training, and support of SMT programming software.- Chemical process qualification of no-clean paste for a family of products.- SMT line support, including screen printing, placement, and reflow.

Bachelor Of Science (B.Sc.), Mathematics And Engineering

Mathematics and Engineering is a program that covers traditional mechanical engineering study against a backdrop of advanced mathematics..

Education record