Expert Details
Engineering and Operations in Thick Films, Components and Fuel Cells
ID: 725069
Pennsylvania, USA
He has extensive Designing for Manufacturablity (DFM) experience spanning his entire career. This includes materials and process selection, vendor selection, prototyping, pilot and production validation assuring DFM targets of cost, yield and throughput are met. He has used lean manufacturing techniques to optimize processes and products prior to and after launch, scaleup and retirement / replacement. He has also designed processes and products with specific quality objectives in mind, again in support of the larger goal of designing for manufacturability.
He has extensive engineering project management experience with new and improved processes, new product introduction (NPI) and launch, buy / make decisions and renovation / construction projects.
He has directed engineering groups in support of operations and production management, during prototype, scaleup and through to handoff to high-volume production. This has included transitioning operators with process ownership out of development and to production's control.
He is a trained lead ISO9000 lead auditor, having brought a quality system for a 100 person operation into compliance to ISO 9001, through ISO 9000 and to QS 9000 in 18 months time.
He has developed methods for rapidly and systematically evaluating anode and cathode formulations in solid oxide fuel cell and solid oxide electrolyzer cell applications, including ceramic tape and thick film paste materials.
Consulting as a Patent Engineer / Technical Writer. The assignments have given him experience combining technical and business expertise to add value to Fortune 500 companies' IP portfolios.Consulting as an Engineering / Operations expert. The assignments have combined his hands-on style and experience to resolve real-world problems using a structured and disciplined approach, providing long-lasting solutions to basic process and operations problems.
Education
| Year | Degree | Subject | Institution |
|---|---|---|---|
| Year: 1992 | Degree: MBA | Subject: Business Admin | Institution: University of San Diego |
| Year: 1986 | Degree: BS | Subject: Ceramic Engineering | Institution: Rutgers University, College of Engineering |
Work History
| Years | Employer | Title | Department |
|---|---|---|---|
| Years: 2007 to Present | Employer: Undisclosed | Title: Engineering / Operations / Technical Writing Consulting | Department: Undisclosed |
Responsibilities:Engineering / Operations Consulting – He provides clients with expert Project Management, Product Development, Manufacturing Documentation / Quality System development and optimization services. Areas of expertise also include Manufacturing / Process Engineering, Lean Manufacturing, Designing for Manufacturability (DFM), New Product Introduction (NPI) and facilitating change (Change Agent).Patent Engineering / Technical Writing Consulting – He prepares patent applications and drawings for Fortune 500 organizations for submission to the USPTO. This includes extensive contact with clients to turn abstract concepts and sketches into comprehensive, high value-add IP protection. |
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| Years | Employer | Title | Department |
| Years: 2006 to 2007 | Employer: Undisclosed | Title: Principle Engineer / Manufacturing Engineering Manager | Department: Undisclosed |
Responsibilities:Materials Development – He developed an in-house Solid Oxide Fuel Cell (SOFC) material set (ceramic tapes and pastes) in 9 months, exceeding the performance of the existing material set which took more than 5 years to develop.Construction Management – He managed from design concept to acceptance testing a doubling of testing capacity and a consolidation of processing equipment, including budget and schedule responsibility. Equipment Specification and Selection – He selected and installed increments of capacity consistent with R&D and Pilot demand, including ceramic tape and paste fabrication, hole punching and lamination. Process Scale-up – He increased capacity by a factor of 100 in 6 months, on-time and under budget. Capacity and Materials Planning – He developed models to optimize materials requirements and schedule. Cost Modeling – He developed cost models specific to individual designs to determine process/material cost drivers and then developed and implemented plans to improve processed and drive cost down. Systems Development – He established systems for tracking work orders, drawings, and document control. |
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| Years | Employer | Title | Department |
| Years: 2002 to 2005 | Employer: Undisclosed | Title: Manufacturing Engineering Manager | Department: Undisclosed |
Responsibilities:Strategic and Capacity Planning: He modeled entire factory process flow. Identified current and upcoming bottlenecks, and eliminated them as installed and demonstrated capacity increased.Process Cost Modeling: He developed in-house / outsource cost models for existing processes, proposed changes/improvements to processes as well as entirely new processes. Process Development and Transfer: He developed high volume / cost effective processes for water jet cutting and electroplating of nickel, both with yields in excess of 98%. Operations Management: He directed the Manufacturing Engineering group (Engineers and Technicians) focused on designing for manufacturability and test, reducing cost and cycle time, improving reliability, yield and throughput of substrates and assembled LED light arrays. Knowledge Library: He designed, developed and maintain a multimedia knowledge library for planning, scale-up, equipment and process development for the Mfg. Engineering Department. Factory Scale-up: He scaled all processes to increase capacity by a factor of 1,000 in under 2 years. Yields increased from less than 5% to over 90%. |
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| Years | Employer | Title | Department |
| Years: 1995 to 2002 | Employer: Undisclosed | Title: Manufacturing Engineer / Manufacturing Engineering Manager | Department: Undisclosed |
Responsibilities:Strategic and Capacity Planning: He executed the transition to high volume / low margin operations in support of the business plan.Change Agent: He identified filling process automation need, drafted proposal to senior management, minimized project risk and achieved performance / cost goals while earning operators' acceptance. Product Transfer to Production: He developed the system to smoothly transfer products from the research lab through development and into high volume production. QS 9000 / ISO 9001 Implementation: He led activities to bring the firm to ISO 9002, through ISO 9001 and into QS 9000 Quality System Certification. Research and Development: He led Research and Development activities to successfully develop materials for high frequency / high power / high reliability electronic modules on Aluminum / Silicon / Carbide substrates. |
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Additional Experience
| Vendor Selection |
|---|
| Extensive experience in Thermistors, Thick Film Paste and Tapes and Solid Oxide Fuel Cells (SOFC), Low Temperature Cofired Ceramics (LTCC), Multilayer Ceramic Capacitors (MLCC) and cofired ceramic electronic packages. This includes sourcing of raw materials and equipment, process development, introduction to manufacturing and scale-up. |
| Other Relevant Experience |
|---|
| Much of his experience is aimed at product/process development and subsequent introduction to manufacturing. As such, significant effort to determining materials, process, quality requirements and documentation minimize re-engineering or other surprises as volume production is realized. |
Fields of Expertise
cost engineering, manufacturing cost control, design for manufacturability, process engineering, production engineering, quality engineering, engineering project management, new product development, new product development management, production management, quality auditing, rapid product development, lean manufacturing, QS-9000 quality system requirements, ceramic engineering, ISO 9000 auditing, quality evaluation, ISO 9004, ISO 9002, ceramic material reliability improvement, vendor quality auditing, ceramic quality control, ISO 9000 series quality system standard, design-for-quality, capability study, ceramic material selection, product development cycle time, project cost engineering, quality standard, manufacturing process development, ceramic material, material product development, continuous quality improvement, ceramic package, control process, life-cycle costing, cost control, design process, total quality control, quality control, production control, ceramic processing, business process re-engineering