Work experience
Jan 2011-Feb 2014 Nextek Inc. Madison AL
Product/Process Engineer
Summary: The primary purpose of my role: To support improvement of existing and New processes, design, install, configure and maintain manufacturing systems to reduce cost, improve equipment reliability, and develop best practices with in the production process. The main focus of my process engineer work is on maintaining reliable and safe manufacturing systems, while improving quality, overall equipment effectiveness (OEE), production rates, efficiencies, yields, costs and changeovers. I was also a part of the plant staff driven to identify, develop and deliver innovative solutions that improve process capability and production volume while maintaining and improving safety and quality standards.
Support production and maintenance in improving process reliability and performance. Key success factors include reducing equipment downtime and scrap, improving line performance and quality throughput, reducing changeover times, and improving the plant’s overall approach to preventive and predictive maintenance
Facilitate process/continuous improvement. Identify cost-savings and process improvement projects and move them from concept to implementation. Drive continuous improvement by developing and implementing systems and process improvements that optimize all phases of the production process; be actively involved in the development and implementation of long term improvement plans.
Create and maintain process flow, Standard Operating Procedures and line capability and performance documentation.
Develop and maintain error proofing methodologies.
Support, cost, estimate and document all engineering changes.
Initiate actions to prevent the occurrence of any quality non-conformances related to product, process and systems.
Provide technical inputs for incident investigation, root cause analysis and corrective action.
15-20 years of relevant experience in the Process/Program engineering environment and 8-10 years of that being working with products for the Department of Defense. (DOD)
Strong mechanical, electrical and manufacturing process skills/experience.
Strong communication skills to “see the big picture,” and work through ambiguity and change.
Detailed Role at Nextek (Majority of products were with the DOD).
In my role at Nextek as a Process/Product Engineer I worked with the Product managers and various manufacturing vendors to innovate creative ways to make new products and keep all facets of the manufacturing on schedule while maintaining great quality.
Developed assembly Flow paths and production line work instructions with Aegis System Software to ensure all of customers requirements were met.
Generate setup sheets for each product for efficient product build times and to minimize production cost so we as a team would meet or exceed customers needs.
Worked with various customers files to create PCB stencils and other tooling that may be needed to process the assembly thru the build.
After each run, I would conduct a 1st. Article buyoff with Customers drawing and Bom, verifying part marking, placement, polarity and solder joints met the IPC class of the assembly. Once a 1st. article is complete as a good unit. I would build a AOI (Yes Tech) program and look at all components part marking, placement, polarity , solder joints and lead banks for shorts, opens or damaged part.
Defect data would be collected from the AOI system to go back and make adjustments if needed to the SMT build process for better 1st time test at the AOI system.
Programmed the selective solder machine (Juki) for the flux and soldering process and debugged the problems with the program in areas on the PCB that will not solder correctly.
Created the Refolw oven profiles for each product to have each board at its optimum temperatures.
Setup Pneumatic, electric and manual press for anything from a swange to a press fit connectors.
Emergency First Responder, Trained in First Aid, AED and member of Nextek / G Es 6S teams. Worked several 6s projects.
Provide support for all aspects of the production process
Sept 2009-Dec 2010 Yulista Management, Huntsville, AL
Integration Lab Manager/Product Engineer
Supported The Prototype Integration Facility (PIF) by leading the Special Projects electronics laboratory on all classified and non-classified projects.
Explored Technology Insertion (TI) strategies to minimize support burdens, reduce resource requirements, and reduce the supportability risks related to obsolescence leading to improved reliability and maintainability on systems and components and decreased the logistics footprint through the minimization of special tools and test equipment.
Served on Wireless Internal Combustion Engine (WICE) Integrated Product Team (IPT) as production Subject matter Expert (SME) to ensure producibility and Manufacturability of design.
Conducted market research and analysis to determine the availability, suitability, operational supportability, interoperability, safety, and ease of integration of the considered and selected procurement solutions to support buy/make production decisions and TI strategies while being ever cognizant of the Reliability and Maintainability (RAM) impact on the system
Applied Lean Manufacturing techniques and assisted in the development of the Integrated Master Plan (IMP) and Integrated Master Schedule (IMS) to depict the overall PIF effort.
Developed and implemented training program to introduce PIF Operating Procedures (POP) to new and current employees ensuring compliance with ISO 9000 standards.
Responsible for interviewing and selection of personnel to ensure proper staffing levels to execute assigned projects
Developed and organized workflow and implemented in-process Quality Control points resulting in reduction of failures and non-conformances by 68%.
Identify work force requirements, Train and cross training of employees.
Monitor employee performance for adherence to documented procedures.
Monitored quality records and held regular documented meetings with employees and PIF Quality Management Review Team to review inspection data.
Maintained production equipment and ensure prompt repair and adjustments are done as required.
Initiated actions to address process or equipment deficiencies.
Provided timely and properly sequenced production of assemblies as required by customers.
Conducted monthly department meetings to review items on the department’s agenda form and other relevant subjects forth coming.
Assisted with dynamic testing of military maintenance systems, communication systems.
Assisted with all forms of lab testing operations.
Interfaced with engineers, supervisors, managers, suppliers and customers on the requirements of all assemblies.
Certificate of Completion of Cable Processes IAW IPC/WHMA-A620 Rev. A from (PIF)
Certificate of Completion Soldering Processes IAW J-STD-001 Rev. D Class 3 (PIF)
Certificate of Completion Interpreting Engineering Drawings (PIF)
Feb 2009 to Aug 2009 Engineering Tec...
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