Intellex Acquires Expert by Big Village

We're thrilled to announce that Intellex has acquired Expert by Big Village, effective March 22, 2024. This strategic move enhances our capabilities and strengthens our commitment to delivering exceptional solutions to our customers.

Stay tuned for more updates on how this acquisition will benefit our clients and experts.

For inquiries or more information, please contact us at info@intellex.com.

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Expert Details

Quality Engineering, Semiconductor Packaging & Automotive Industry Specialist

ID: 740177 United Kingdom

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Expert is a seasoned Engineering and Senior Engineering Quality Manager with over 35 years of experience across various industries, including semiconductor packaging, automotive components, and fabrication. He has spent more than two decades leading New Product Introduction (NPI) initiatives for automotive semiconductor products and has developed cutting-edge System-in-Package (SiP) assemblies and MEMS solutions, supplying over 90 million units annually.

At Sensata Technologies, where he worked for 23 years, Expert served as a Subject Matter Expert in semiconductor packaging, particularly in the assembly and qualification of SiP, SiC, MEMS, and custom advanced packaging solutions. He led the development and implementation of robust quality management systems (QMS) that complied with industry standards such as ISO 9001, IATF 16949, and ISO 45001, helping maintain a near-zero field failure rate (less than 0.5 ppm) for products used in automotive applications.

Expert also managed critical aspects of process engineering, quality assurance, failure analysis, and customer relations, working with prominent automotive manufacturers like BMW, Nissan, Ford, and Hyundai. He led global supplier audits and ensured compliance with quality standards through continuous improvement and defect prevention strategies.

Prior to Sensata, Expert held senior quality engineering roles at Faurecia, Lucas EUI Systems, and Lydmet Ltd, where he established and led quality control systems, supplier development, and customer support in highly competitive industries. His expertise includes failure mode and effects analysis (FMEA), statistical process control (SPC), advanced product quality planning (APQP), and business continuity planning.

Education

Year Degree Subject Institution
Year: 1983 Degree: HND Subject: Cat Metal Technology Institution: Mid-Gloucester College

Work History

Years Employer Title Department
Years: 2024 to Present Employer: Undisclosed Title: Semiconductor Consultant Department:
Responsibilities:
Engineering quality management for Semiconductor Industry.
Years Employer Title Department
Years: 2000 to 2023 Employer: Sensata Technology Ltd. (Formerly Swindon Silicon Systems) Title: Quality Engineering Manager Department:
Responsibilities:
• Led a team of professional engineers, representing Process Engineering, Reliability & Qualification, Failure Analysis, Quality Assurance and Control.
• Management of customers including Ford, Mercedes, Hyundai, Nissan, and Great Wall.
• Involved with the problem solving and development of preventive and corrective action programs to resolve end-customer concerns.
• NPI Team member from start of project, including feasibility, process, product and supplier selection. Provided process control, APQP, qualification & reliability for all company projects and product change management.
• Semiconductor Assembly Subject Matter Expert embedded in all SIC. SIP, MEMS, Discrete and Custom Advanced Packaging.
• Spearheaded product development initiatives in response to customer concerns, audit findings, and supplier improvement efforts, focusing on defect prevention, process yield enhancement, and the creation of comprehensive supplier development roadmaps and Business Continuity planning.
• Developed and amalgamated QMS/EMS/EHS procedures and systems that served as a complete Business Management System, compliant with ISO9001, ISO/TS16949, ISO45001 & ISO14001.
Years Employer Title Department
Years: 1996 to 2000 Employer: Faurecia Title: Senior Quality Engineer Department:
Responsibilities:
• Supervised a team of quality engineers establishing a QS9000 culture in an automotive seating manufacturing facility. Deputized for the Quality Manager working directly with senior management team on a daily basis.
• Created and implemented all quality control systems and methods of a new manufacturing facility to produce high quality components for Honda and Rover. • Directly responsible for quality of all new product implementation including (advanced product quality planning), PPAP (prototype product approval process), process FMEA (failure mode and effects analysis), SPC (statistical process control) & MSA (measurement system analysis). Lead auditor for internal and supplier audits covering all aspects of quality.
• Drove continuous improvement and supplier development programs. Incorporated co-ordinate measurement into the production line. Controlled to ensure, high dimensional capability and meet ever more stringent quality requirements. Developed quality training programs for all levels of personnel within the business.
Years Employer Title Department
Years: 1992 to 1996 Employer: Lucas EUI Systems Title: Senior Quality Engineer Department:
Responsibilities:
• Responsible for the successful implementation of ISO 9001 & RG 2000 for the manufacturing and design sites of high precision components for electronic injection units, both machine manufacture and assembly.
• Developed and implemented a continuous improvement program dealing with all aspects of quality, resulting in a significant reduction in quality rejects, benchmark quality systems and improved customer relations.
• Managed quality management reviews reporting directly to the Board of Directors covering all aspects of quality and continuous improvement.
• Served as the AQP engineer for new truck products, responsible for the full spectrum of quality assurance and control in a high precision automated machining, assembly and test plant, responsible for its own design and development serving the diesel automotive industry.
• Implemented training programs on quality skills developing the quality culture for a quick response continuous improvement environment at all levels of the business.
Years Employer Title Department
Years: 1989 to 1992 Employer: Lydmet Ltd. Title: Q1 Coordinator Department:
Responsibilities:
• Successfully implemented Ford Q1 and IS09002 quality systems into one of the most technologically advanced foundries in Europe, regularly audited and approved by customers world-wide, including Nissan, Ford, Volvo and Expert Deere.
• Developed state of the art gauging methods including image analysis, CNC profile measurement, and developing computer interface gauging in a wide range of quality control activities.
• Introduced statistical process control to a large variety of quality control systems of a high repetition foundry manufacturing automotive components.
Years Employer Title Department
Years: 1987 to 1989 Employer: Cannop Foundry Title: Quality/Technical Manager Department:
Responsibilities:
• Recruited to implement quality systems to IS09000 standard, significantly improving metallurgical and dimensional control of a wide range of general engineering castings supplied to a variety of manufacturing industries.
• Established metallographic inspection methods to enable production of a wide variety of cast iron structures (including SG iron), and introduced statistical analysis for metallurgical and dimensional control.
Years Employer Title Department
Years: 1985 to 1987 Employer: Lydmet Ltd. Title: Laboratory Supervisor Department:
Responsibilities:
• Co-ordinated and controlled laboratory activities to provide metallographic inspection and test support to a high repetition ferrous foundry, implementing a variety of control techniques to ensure high standards of material analysis and compliance to stringent specifications.
• Completed 4-year indentured foundry technician apprenticeship.

International Experience

Years Country / Region Summary
Years: 2005 to 2023 Country / Region: Malaysia, Thailand, Singapore Summary: Audit Suppliers for initial Vendor evaluation, annual assessment & Failure analysis.
Escort Customers, Present Project & Failure Analysis material to potential Suppliers.
Years: 2010 to 2023 Country / Region: China Summary: Audit Suppliers for initial Vendor evaluation, annual assessment & Failure analysis.
Present Project & Failure Analysis material to Customers and potential Suppliers.

Career Accomplishments

Associations / Societies
International Microelectronics Assembly & Packaging Society – IMAPS (Member)

Fields of Expertise

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