Senior Manufacturing / Process Engineer with over 25 years in manufacturing and process optimization across aerospace, medical, and high-volume environments. Led cross-functional initiatives to enhance yield, reduce costs, and improve manufacturability and process reliability. Expertise in mechanical and electrical processes, equipment, tooling, and root cause analysis, driving product quality and compliance with quality standards.
· Maintained manufacturing process documentation and ensured current requirements were reflected in production documentation.
· Developed balanced manufacturing processes based on production demand and takt-time requirements.
· Evaluated and defined appropriate tools and equipment required to support manufacturing processes.
· Designed and optimized manufacturing line layouts to improve process flow and production efficiency.
· Managed engineering changes and supported implementation of changes into manufacturing.
· Investigated process issues and implemented preventive and corrective actions to improve manufacturing performance.
· Supported new product development and manufacturing readiness activities for the business unit.
· Certified operators for critical manufacturing operations, ensuring personnel met requirements for safe, timely, and quality-compliant assembly.
· Prepared work instructions and production procedures used for operator training and standardized execution.
· Led new product development (NPI) activities from concept through pilot validation (PV) and mass production readiness.
· Coordinated and reviewed technical documentation, including CAD drawings, BOMs, SOPs, specifications, and validation plans, ensuring accuracy and compliance.
· Managed and implemented Engineering Change Orders (ECOs) in collaboration with customers, aligning technical specifications with business requirements.
· Collaborated cross-functionally to resolve mechanical and electrical issues, ensuring product reliability and manufacturability.
· Improved manufacturing quality by reducing foreign material defect rate from 2.3% to 0.8% through implementation of process controls and cleanroom best practices.
· Delivered 50% component cost reductionthrough component optimization while maintaining product quality and compliance requirements.
· Monitored quality and development KPIs, providing regular reports to leadership to inform strategic decision-making.
• Designed and implemented manufacturing procedures, visual aids, and work instructions to standardize production processes.
• Interpreted engineering drawings and translated product requirements into manufacturing processes.
• Trained and qualified new personnel and operators for specialized manufacturing operations based on work instructions, IPC-610, and company quality requirements.
• Programmed and performed basic maintenance on Automated Optical Inspection (AOI) equipment.
• Developed and implemented poka-yoke fixtures to improve process control and prevent manufacturing errors.
• Implemented Engineering Changes (ECOs) into production processes.
• Developed and implemented manufacturing procedures supporting production operations.
• Applied Lean Manufacturing techniques including 5S, Kanban, and standardized process flow to improve production performance.
• Introduced new product designs into manufacturing lines, supporting first-article and production implementation activities.
• Performed production-line productivity analysis and implemented Engineering Changes (ECOs).
• Supported inventory, Material Review Board (MRB), scrap, and rework reduction activities.
• Supported product transitions from U.S. manufacturing sites into production operations.
• Performed electrical test yield analysis to identify opportunities for scrap reduction and process improvement.
• Developed test programs for cable and harness manufacturing.
• Provided technical troubleshooting training to technicians.
• Provided engineering support for products returned by customers.
• Supported implementation of test processes for new products.