Thad Casey Email & Phone Number

Malta, Ny

Startup Clients - Innovative Manufacturing Consultants (IMC) leads startups with engineering expertise to bring their innovative technology out of the lab and into full scale production.- Working collaboratively with startups, IMC leverages our industry experience to evaluate product design details and ensure it meets customer needs.- IMC prepares the startup with the professional specifications, drawings, and manufacturing strategies required to deliver the product to market on time, on budget, with industry leading quality. - Consulting services include - Product Design from Prototype to Production - Design for Manufacturability - Solid Models and Detailed Drawings - Technical Customer Discovery - Product Specification Development - Manufacturing Supply Chain - Make vs. Buy Strategy - Manufacturing Process DevelopmentManufacturing Clients- IMC is a technology solutions company. We specialize in supporting US based manufacturers by quantifying ways technology can help grow their business. Through development and integration of CAD/CAM driven CNC processes and advanced tooling, IMC reduces cost, improves quality, and increases productivity in a safer working environment.- IMC’s core focus is development of manufacturing processes on the shop floor. Critical to that success is finding the right balance of technology and innovation to meet the customer’s business needs with their workforce. We also consult on PLM, ERP, DNC, and Factory Monitoring to drive Lean processes through people, hardware, and software.Client Highlights- Director – Manufacturing Incubator at the Tech Valley Center of Gravity – Publicly Funded- NYSERDA Certified Entrepreneur In Residence (EIR)- Products including wastewater energy capture, wireless electric vehicle charging, aerospace wiring clips, medical devices, medical research equipment, nitrogen filling stations, silicone consumer goods, coffee manufacturing, precision machining and fabrication shops.

Malta, Ny

Vorpal lets you play your favorite tabletop games with family and friends remotely. Successfully funded on Kickstarter in early 2020, delivered to all backers that fall, and transitioned to an e-commerce business.- Prototyped and finalized physical product and packaging designs- Established and qualified a supply chain during the global pandemic- Designed, developed, and optimized the lean manufacturing process and converted from batch to concurrent workflows- Completed all procurement, manufacturing, packing, shipment, and customer support related to the physical products- Delivered all Kickstarter units and ongoing e-commerce orders on time- Lead business development in the tabletop role playing games segment including strategic partnerships, community engagement, and social media content

Clifton Park, Ny

- Promoted to Engineering Manager within 9 months of joining TPL to establish an engineering team and foundation for growth within the organization.- Built a team of 10 Engineers and Drafters distributed across the four TPL locations.- Deployed the use of three dimensional model driven CAD drawings and CAM strategies. Drove the cultural change to CAD/CAM/CNC based manufacturing enabling significant reductions in cost and cycle while improving quality. Critical to this success was envisioning a process that was fast and flexible yet revision controlled, enabling production manufacturing techniques to be integrated in a job shop environment. - Led the selection, installation, and implementation of ten pieces of CNC equipment. Decisions were based upon data and knowledge from baseline manufacturing processes. - Implemented a Product Lifecycle (PLM) system to handle revision control and manufacturing release of TPL drawings and intellectual property. A standard industry product was selected and customized to meet the specific needs of the business. Integrated PLM with the Enterprise Resource Planning (ERP) system to streamline the process and minimize duplication of data creation with simplification and automation. - Organically developed a world class Reverse Engineering process to support aftermarket replacement parts. Process included three dimensional laser scanners, material analysis, and precision hand tools. Work was completed in-house and at the customer’s site. Critical to the process was not simply the measurement of the part but establishing OEM form, fit, and function from a worn sample. - Supported customers with technical expertise; troubleshooting turbine operational issues, clarifying sales questions, and executing short cycle replacement parts customized for their turbine.

Clifton Park, Ny

- Reported directly to the President of TurboParts- Conducted shop walkthroughs and quality audits at over thirty key suppliers - Establish and maintained metrics for continuous improvement in quality and on time delivery

Latham, Ny

- Reported directly to the Vice President of Retrofits- Managed all technical and commercial aspects of large scale steam turbine and generator retrofits. Retrofits included upgraded internal components designed by Hitachi Power Systems. Contracts ranged from $5M to $50M. - Single point of contact for the Customer, MD&A, and Hitachi through all phases of the project including: proposal development, clarification meetings, contract negotiations, design reviews at Hitachi Works in Japan, international shipping logistics, and installation/commissioning support.

Schenectady, Ny

Lead Design Engineer – High Pressure/Temperature Shells and Stationary Structures- Owner of the combined cycle shell platforms- Focus on total lifing methodologies and damage mechanics- NPI and requisition execution and design integration with multiple component and commercial teamsMechanical Design Engineer – Advanced Last Stage Buckets- Lead engineer for NPI development of large titanium blades- Focus on manufacturing process improvement and development to drive cost and qualityMechanical Design Engineer – ACDP Leadership Program- Successfully completed corporate leadership program titled the Accelerated Career Development Path (ACDP) with a concentration in Steam Turbine Blading Technology “for rapid development of technical expertise in specific technology areas with active mentorship from the engineering leadership team”.- ACDP rotations included all aspects of component ownership: o Detailed Design Process and Methodologies o Design Practices, Automation, and Drawings o FEA, Dynamics, Lifing, Creep o Manufacturing Process Development, Quality, Total Product Cost o Component Testing and Validation o Manufacturing and Field Support- 6-month international assignment in Florence, Italy at GE Nuovo Pignone. Project focused on technical and commercial feasibility of upgrading design and manufacturing processes of turbine blades from simple 3-axis milling to three dimensional profiles requiring 5-axis milling. Lead GE Recruiter – Clarkson University- Lead engineering recruiter for GE Internship/Co-Op and Edison Engineering programs- Completed behavioral based interview training and certification

Master Of Science, Mechanical Engineering

Activities and Societies: Zeta Nu Fraternity

Bachelor Of Science (B.S.), Mechanical Engineering

Activities and Societies: Zeta Nu Fraternity