William Mccabe Email & Phone Number

Helping rapidly growing companies scale up their manufacturing operations through the intelligent application of automation, design for manufacturing principles and tooling design.

Palo Alto, Ca, Us

• First manufacturing hire; in addition to a manufacturing engineer I was the acting buyer, production planner, and quality engineer.• Designed and assembled a wing stand, allowing a single technician to move and orient the wing through all the wing assembly stations. Previously it required four people to move the wing multiple times during integration.• Designed and fabricated/purchased numerous other assembly tools, test stands, and lifting fixtures; always with the goal of reducing the dependency on highly skilled technicians.• Worked with the Hardware team to improve automation of end of line testing, giving KH the flexibility to easily move hardware manufacturing in or out of house.• Created standards for and authored assembly documentation, standard processes, wire harness drawings.• Identified dozens of components that could be replaced with COTS equivalents; performed most of the design work necessary to make those changes.• Managed Heaviside’s first hardware contract manufacturing operations. Provided documentation and technical support as well as project management.• Created and managed the CapEx justification workflow; ensuring that we had a consistent and thorough way of determining ROI.• Established relationships with local vendors to provide fabrication expertise that was too expensive to in-source.• My team created and owned the PFMEA and corrective actions for all production• Built a team of engineers and technicians to bridge the gap between the design and production environments. We built prototypes, provided design feedback, created work instructions and processes, and developed the tools to support hardware and mechanical assembly, vehicle integration, and composites manufacturing.

Austin, Texas, Us

Across all engineering roles at Tesla, key engineering accomplishments include:• First dedicated equipment engineer for the Motor Rotor line; increased line availability from 60% to >85% in first 6 months despite no prior familiarity with many of the processes.• Worked closely with Manufacturing Engineering to purchase, validate, and launch more than $15M of new equipment. Supported Factory Acceptance Tests and Design Reviews. Continued to work directly with vendors to improve and upgrade equipment after installation.• Identified opportunity for improvement in weld inspection process. Selected ultrasonic inspection as a superior approach. Worked with a local contractor to develop, test, and initially outsource the process. Purchased equipment to bring the process in-house, increasing sampling rate, and saving $600k/year (7 month ROI).• Developed variety of tools for Maintenance and Production, ranging from calibration worksheets and visual basic programs to mechanical and pneumatic lift assists to increase safety and improve availability of the line.• Worked with overseas vendor to automate a lengthy warm-up process. Used data-driven approach to overcome vendor's initial concerns. This automation reduced total PM downtime by 15% and labor hours by 50%.• Planned and executed successful reconfiguration of the line to allow 10% of total space to be reallocated to new manufacturing processes.• Purchased and installed a conveyor system to replace existing hopper feed system, reducing headcount by 1 FTE/shift and eliminating the largest source of downtime on the line.• Created Equipment Maintenance Specifications and process records to standardize and facilitate maintenance training across multiple shifts.• Partnered with NPI and Design teams to introduce prototypes and part changes to the line. Modified equipment, programs, and recipes as needed while minimizing impact to ongoing production.

Austin, Texas, Us

Across all management roles at Tesla, key leadership accomplishments include:• Managed team of 14 Equipment and Process Engineers and Engineering Technicians across 4 manufacturing lines.• Inherited two teams who were largely not willing to communicate, successfully integrated into one cohesive equipment and process team.• Worked with maintenance management to create a champion system. Champions are experienced maintenance technicians trained by Engineering to be the local expert on particular pieces of equipment. Personally created the syllabi and performed much of the training.• Standardized expectations for different levels of engineers, facilitating increased transparency into performance reviews and promotion decisions. These standards were then adopted throughout the department.• Created the first widely utilized practical escalation procedure outlining roles and responsibilities for Production, Engineering, and Maintenance. Emphasized Maintenance ownership of the equipment for faster response. After implementation, escalations to engineering dropped by >50% without a decrease in availability.• During my tenure has manager, throughput on Rotor as increased 15%.

Austin, Texas, Us

Austin, Texas, Us

Austin, Texas, Us

Plano, Texas, Us

• Improved yield and production capacity by designing and modifying fixtures, working with technicians to create more reliable assembly techniques. • Redesigned similar assemblies to use common parts, reducing costs and improving material lead-time. Standardized cathode design across an entire product family, reducing cathode cost by 40%.• Developed new brazing and welding technologies to reduce reliance on expensive sub-contractors. Performed metallurgical cross-sections and industry standard strength testing to qualify new process.• Managed new component manufacturing projects, a significant departure from CPI’s typical products. Created new documentation standards. Applied and adapted CPI strengths to new opportunities. Built strong relationships with a new customer, helping them redesign products for improved manufacturability without sacrificing performance. Designed all braze and weld interfaces at customer request.• Became a certified welder and furnace operator in order to personally assemble prototypes and better understand technician work load. Learned to perform own cross-sections and analysis to reduce strain on the metallurgy lab.