Experienced Manufacturing Process Engineer specializing in all aspects of SMT Assembly. Extensive experience in both OEM and EMS Contract Manufacturing environments for both domestic and foreign based companies. Low volume/high mix to high volume manufacturing serving a wide range of products including consumer, automotive, military, high speed data processing, medical, telecommunications, safety and various industrial applications.
Well rounded process development knowledge
Wide variety of equipment programming, troubleshooting, and debug skill sets
Well versed in DFM, Failure Analysis, Process Flow, line balancing
Lean Green Belt Certified
Strong analytical skills
Ability to interface and communicate to all levels of organization from production to CEO level and customer both verbally and in written form
Ability to multitask and handle multiple projects and responsibilities
Senior Process Engineer (SMT)02/2008 － Current4Front Solutions LLCErie, PA
Lead team of Engineers in SMT Department.
Responsibilities include all aspects of development of process, programs, and tooling for Prototypes (NPI) and support production across multiple configurations of assembly lines.
Provide training and mentoring of operators, production technicians, engineering technicians/engineers to improve knowledge and skill sets. Oversee training programs of personnel internally and externally.
Monitor and address equipment, quality and throughput issues by developing comprehensive SMT performance metrics, quality analysis tools, real time production monitoring and dispatch displays for production, engineering and management.
Perform equipment, materials, tooling and process evaluations and develop specifications for equipment to support production requirements. Evaluated and approved screen printers, placement machines, AOI, SPI, inspection and rework tooling, consumables, cleaning chemistries, solder pastes, stencils and other process tooling.
Managed relocation and installation of assembly lines during expansion to new factory without jeopardizing customer delivery demands. Grew department from one shift, one assembly line to two shift, four assembly lines. Developed factory floor layout of equipment for architects to plan infrastructure installation. Coordinated purchase, delivery, installation of equipment and facilities with multiple vendors and outside services within budget and time constraints.
Coordinate equipment and line reconfigurations to satisfy changing product technology and through put requirements. Work closely with equipment vendors and production to ensure smooth implementation.
Implemented machine capability and verification testing for placement and screen print to ensure accuracy and repeatability of process.
Drove implementation of level four component traceability across all SMT production lines, including revamping company labeling methodology to 2D labels, designing and installation of flexible scanning systems, setting up and modifying equipment software to manage trace requirements. Developed method to eliminate MES communication between scanner and trace system to eliminate downtime and errors cause by communication time outs and missing data.
Developed standard operating procedures, work instructions and training for equipment setup, operation and programming. Conduct training sessions with operations and engineering.
Partnered with paste manufacturers and industry expert to developed a comprehensive, next generation solder paste evaluation test plan. Project and results featured in 2017 SMTAI paper and presentation.
Spearhead introduction of new technology and methods including 0201 & 01005 print/place/reflow. QFN assembly and rework, .4mm bga/csp, various miniature bottom terminated devices as well as flex and rigid flex circuit assembly process and tooling.
Supported Assembly and manufacturing of mechanical fuel control systems for jet airplanes, both civilian and military.
Revamped site capacity planning tool using data from SAP to improve accuracy of labor levels. Maintained and presented monthly capacity outlooks to upper site management and all departments.
Mentored college intern/ co-op to develop site OEE measurement project.
Prepared weld department samples and was primary point of contact between off-site lab and weld department to address issues.
Developed a measurement and grading process to bin spring valves based on spring strength. Eliminated trial and error spring selection during installation and testing, reducing unnecessary rework of valve assemblies.
Obtained Lean Green Belt Certification by implementing lean tools to increase throughput of manual assembly of fuel control systems from 2 units per week to 20 per week to meet customer demand. Facilitated second Lean project to improve manual assembly cell for a different customer, improving throughput from 4 units per week to 20 per week.
Process Engineer / Engineering Coordinator10/2002 － 10/2006Keihin Carolina Systems TechnologyTarboro, NC
Responsible for supporting SMT including programming, NPI, Process Development and improvements, equipment evaluations, product gate reviews with management, quality and downtime improvements for automotive assemblies.
Worked with main Japanese facility and process group to implement Pb-Free solder process for SMT.
Promoted to Engineering Coordinator for SMT Department overseeing activities of salaried and hourly engineering personnel across 3 shift operation (18 total) . Managed department budget, coordinated AOI and reflow oven evaluation to improve lead free processing and inspection, implemented a non-Japanese reflow oven to improve flux management of high rosin based Japanese flux. Localized (US based) stencil supplier of electroformed stencils, reducing cost by 66%.
Completed a comprehensive process evaluation/ best practices comparison with main Japanese facility, resulting in Japanese facility to adopt new methods of oven profiling, improving their equipment PM schedule and process. Gained respect and trust of Japanese counterparts which resulted in increased leeway to source and implement equipment and processes independent of Japan, including non-Japanese equipment.
Senior Process Engineer11/1998 － 10/2002SolectronCharlotte, NC
Business unit process engineer for medium volume group.
Facilitated building rearrangement of entire assembly floor from stockroom to test to improve flow and increase number of SMT assembly lines from 8 to 12 with additional space for another 4 lines of growth.
Designed, specified equipment, and coordinated installation and setup of a double sided CFM line to build telecommunication relay boards from bare board to boxed product.
Promoted to Process Engineer for NPI group in medium volume hub. Responsible for placement program debug, setup and development of printing and reflow process, SPI and AOI programming, tooling design, Hot air BGA repair
Developed a site tooling tracking system to inventory and track tooling when transferred between buildings on campus.
Education and Training
1997Bachelor of Science:Rochester Institute of Technology - Manufacturing Engineering TechnologiesRochester, NY, USA
Vice President of Tau Alpha Pi National Engineering Honor Society RIT Chapter
Senior Project featured in SMT Magazine to illustrate Industry and Education working together.
Graduated with Highest Honors
1994Associate of Science:Edinboro University of PA - Manufacturing Engineering TechnologiesEdinboro, PA, USA
Received Graduate Cord for Outstanding Student in Engineering Technology Department.
2001Certificate:Dale CarnegieCharlotte, NC, USA
Professional Training on public speaking and personal/ professional skills development.
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Companies Worked For:
4Front Solutions LLC
Keihin Carolina Systems Technology
Rochester Institute of Technology
Edinboro University of PA
Job Titles Held:
Senior Process Engineer (SMT)
Process Engineer / Engineering Coordinator
Senior Process Engineer
1997 Bachelor of Science : Rochester Institute of Technology - Manufacturing Engineering Technologies 1994 Associate of Science : Edinboro University of PA - Manufacturing Engineering Technologies 2001 Certificate : Dale Carnegie
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