Qualification Profile: A highly successful Product/Process Engineer with orthopedic implant, electro-mechanical device, rapid prototyping, and high-volume manufacturing process development experience. Medical device successes include 510K approval and a US Patent (4,959,071) for a minimal bone resecting, posterior-stabilized knee implant. Manufacturing experience includes leading a cross-functional team of technical personnel in developing a multi-million dollar assembly cell from customer specification through to PPAP and product launch. Strong leadership, communication, analytical, problem solving and business operations experience gained through rapid prototyping firm ownership with successful product development in the medical, military, heavy equipment, racing, automotive, electronics and commercial furniture industries.

Core Competencies

• Innovative: Collaborated with Dr. Booth of the Rothman Institute in Philadelphia, PA to design and successfully launch a minimal bone resecting, posterior-stabilized knee implant. Co-developed a completely mechanical error-proofing method for an electromechanical assembly device for a lean manufacturing cell.
• Materials: Implant grade stainless steels, ultra high molecular weight polyethylene, cobalt chrome and titanium. Various engineered nylon, polyethylene, polypropylene, and ABS polymers. Powdered iron, various coated copper wire, cast epoxies, and UV adhesives.
• Processes: Wax casting, hot-forging, powdered iron compaction, centerless grinding, injection and insert molding, coil winding, material joining (ultrasonic and resistance welding), epoxy encapsulation, and fastener assembly.
• Software: Microsoft Office Suite, Microsoft Access, Autodesk Revit (Architectural), Autodesk Inventor, Stratasys Insight (RP), Stratasys Status(RP), Materialize Magics RP, and MYOB (Accounting)

Education

BS, Mechanical Engineering, 1988, Rose-Hulman Institute of Technology, Terre Haute, IN

Licenses

• Registered Professional Engineer, Indiana
• Licensed Teacher, Indiana

Professional Experience

Advanced Techniques, Inc., Indianapolis, IN, 2001-2006

Senior Engineer

• Performed Engineering Analysis and product/process development consultation for customers in the orthopedic and surgical syringe, military communication and transportation, Indy Racing League, aircraft electronics, and retail clothing furniture product lines.
• Managed daily operations of rapid prototype shop including equipment operation and maintenance, sales and accounting.
• Aided in customer production tooling procurement and design.

Delphi-E, Anderson, IN, 1995-2000

Senior Manufacturing Engineer, Ignition

• Initiated lean manufacturing concepts; coordinated design, procurement, and validations of production equipment for multi-million dollars projects.
• Interfaced with customers, vendors and plant operations personnel regularly.
• Performed detailed, worldwide equipment benchmarking and best practices analysis for various assembly operations.
• Authored key process development documents such as: equipment and material purchasing specifications, PFMEAs, vendor and production-site equipment validation procedures, operator instructions and process routers.
• Actively participated in component PPAP approvals.
• Actively participated in the equipment validation process of: dimensional stack-up analysis using GD&T, data collection, and SPC data analysis.
• Assisted in the training of production-site personnel.
• Helped develop and implement comprehensive, critical spare parts strategy for assembly cell.
• Established continuous improvement (kaizen) protocol for new assembly cell.
• Supervised daily tasks of 7 member cross-functional team to a successful installation of new 4-cylinder Ignition System manufacturing cell that was on-time and 18% under budget.

Rapid Design Services, Inc., Anderson, IN, 1992-1994

Contract Engineer for Delphi-E

• Established both internal and external quality systems for the manufacture of the EV-1 electric vehicle battery packs ensuring compliance with ISO9000and QS9000 standards.
• Actively participated in both DFMEA and PFMEA development for electric vehicle battery packs and transmission speed sensors.
• Worked with Mexican Operations to achieve 100% capable and in-control processes for a stalk switch assembly cell.

Biomet, Inc., Warsaw, IN, 1988-1991

Development Engineer, Knee Group

Designed, developed and coordinated the manufacture of orthopedic knee implants and surgical instruments.

• Responsibilities included significant surgeon interface and on-going technical assistance to production areas.
• Successfully developed an innovative knee implant system (U.S. Patent #4,959,071). During the first full quarter of market introduction, this system accounted for 15% of all knee sales and contributed 27% overall growth of the product line.
• Other projects included development of salvage or revision knee implant system, refinement of existing surgical instruments, and design of custom orthopedic implants.