Cemal Sam Duru
Woodbury,MN
Summary
Result-driven Senior Advanced Engineer with over 20 years of experience in research and development (R&D), new product and process development, manufacturing and quality and reliability assurance. Inspired cross-functional collaboration with process manufacturing engineers and managers, and project stakeholders, to identify the source of and, ultimately, resolve a key defects for products and processes, and adherence to high-quality FDA standards. Adept at developing and operating sensing hardware and monitoring software systems to support process monitoring and control for international client. A key contributor to scientific advancement team members of published author in scientific journals and abstracts, particularly in the development of new catalyst and membrane.
Overview
25
25
years of professional experience
Work History
Sr. Adv. Manufacturing Engineer
Aerospace Technologies – Honeywell
MN
09.2024 - Current
- Identify area of process improvement and lead initiatives to enhance efficiency and quality in product development and manufacturing assembly processes for cost and cycle time reductions.
- Applied processing techniques and methods in the manufacture, fabrication, and evaluation of Ring Laser Gyroscope and MEMS based inertial sensors and measurement units (IMUM).
- Collaborate with cross-functional teams, including engineering production, supply chain to address quality concerns and drives continuous improvement system in every step of process and production.
- Perform yield and performance data analysis to monitor process capability, product health trends and drive yield improvements.
- Support knowledge for test equipment and preventative maintenance plans to maintain factory capacity and efficient product flow.
- Managed Engineering Change Order (ECO) and Engineering Change Request ensuring product and process designs complaint.
Senior Quality and Reliability System Engineer
TE Connectivity
Andover, MN
04.2023 - 12.2023
- Designed new sensor systems for medical device to systematically identify, analyze, and prioritize potential failure modes, enhancing safety, reliability, performance and efficiency.
- Conducted test method validation of final products to ensure devices are market-ready, compliant with regulatory standards, and aligned with costumer needs.
- Conducted comprehensive hazard analysis, evaluating factors such as failure effectiveness, severity, potential causes, occurrence, detection, risk priority number and mitigation strategies to minimize risk in new product and process design.
- Delivered measurable result in high pressure environment. Utilize Lean Six-Sigma methodologies to govern engineering standard work practices.
Quality Control and Project Management Engineer
Abbott Lab
Saint Paul, MN
07.2022 - 03.2023
- Performed hardware sensors equipment installation, implementation, operation and monitoring qualification of each Abbott lab. manufacturing plant in overseas operation processing.
- Conduct the test method validation of the final product to make sure the device ready to enter the market as per the standards and needs.
- Managing international sites gathering application and coordination of all activities and tasks to meet quality standards of ISO 13845 and FDA regulation.
- Assisted business user for hardware/software solutions to test their hardware sensors implementation, operation and process. Responsible for leading business for scheduling, building, procurement, deployment, and implementation activities.
Quality and Reliability and Validation Engineer
Consolidated Precision Products (CPP)
Bloomington, MN
12.2021 - 06.2022
- Assisted in the prompt review, evaluation and disposition of specifications and related criteria of each aerospace industry airplane engine casting and parts and use bore scope tools to measure engine casting thicknesses.
- Used the DFMEA for designing new fixture operation systems for airplane engine casting to systematically identify, analyze, and prioritize potential failure modes in the fixture design to enhance safety, reliability, and performance.
- Validated a production process such as production part approval process (PPAP) used to verify a supplier’s ability to reliably and repeatably produce a parts for mass production.
- Executed product and process improvement changes to meet or exceed customer quality expectations.
- Provided additional supervision by auditing the safety and quality of manufacturing employees. Also provided training for corrective actions, specification changes, and engineering change requests.
R&D and Test Application Engineering
3M–Fuel Cell Component Program
Maplewood, MN
12.2014 - 12.2019
- Developed and improved test protocol methods for low cost and high-performance product of Membrane Electrode Assemblies (MEAs) of fuel cell (FC) that helps to produce the electron-chemical reaction over 30,000 different test application with over 15 different test application stations.
- Designed new MEA, prototypes for automotive and fuel cell companies, applied DFMEA for designing new MEA to identify potential failure and risk priority number and mitigation of the hazard and safety for fuel cell test stations.
- Planned, designed, assembled, and maintained processes of MEAs to load fuel cell test stations with different conditions and operation protocols to measure and analysis MEA performances for over dozens of Department of Energy projects and preparing and testing each application for GM, Ford and Toyota, Plug Power FC.
- Provided prototype parts and leveraged opportunity to share expertise with client and subcontractors with multi functional team such as universities Carnegie, Melon, John Hopkins, Purdue universities, and top Institutions National labs. Argonne, Los Alamo’s National Lab.
R&D Engineer CO2 Sensors and CO2 Recycling Project
3M–Fuel Cell Prog.
Maplewood, MN
12.2013 - 12.2014
- Designed and developed a new CO2 sensor cell product in collaboration with a subcontractor for the commercial HVAC market that met both energy efficiency and CO2 reduction parameters.
- Motivated team to creatively resolve challenges, closed working with subcontractor of 3M to meet tight deadlines and meet the needs of the contract’s requirement milestone for Department of Energy project.
Fuel Cell (FC) R&D Application & Quality and Reliability Engineer
3M
Maplewood, MN
06.2001 - 12.2013
- Managed quality control measures across multiple fuel cell projects with leading automotive companies like GM, Toyota, and Ford, as well as fuel cell-related organizations, ensuring the highest product quality and compliance with ISO 9001, AS9100 standards, and other internal and external quality assurance requirements.
- Developed requirement specifications for quality, scope, and timelines, resolving complex issues and achieving near-zero defects (99.999% efficiency) in projects involving 14-micron membrane and catalyst coating processes.
- Established and implemented quality control processes, procedures, and tools, including cause-and-effect risk analysis, while leading the deployment of Lean Six Sigma methodologies for all assigned processes. Conducted design validation, verification, and reliability assessments for fuel cell component operations.
- Prepared and optimized Material Electron Assembly (MEA) testing protocols, improving membrane performance across 15+ stations with consistent and reliable results.
- Conducted high-precision experiments to develop high-efficiency test protocols for MEA performance, evaluating both short- and long-term durability. Analyzed the performance of over 12,000 MEAs to assess durability, humidity, and catalyst and membrane performance for advanced applications.
Education
Master of Science - Project Management (MSPM)
Saint Mary’s University
Minneapolis, MN07.2012
Master of Science - Master of International Business (MIB)
Saint Mary’s University
Minneapolis, MNMaster of Art - Masters of Business Administration MBA
Istanbul University
Istanbul, TurkeyBachelor of Science - Chemistry (Chemist)
Trakya University
Edirne, TurkeySkills
- Process and Product Failure Modes Effects Analysis (PFMEA)
- Corrective and Preventive Action (CAPA)
- 5-Why
- Fish Bone Analysis
- Measurement System Analysis (MSA)
- Non-Conforming Material Reports (NCMR)
- Lab-VIEW Software Test Application Program
- Keyence Digital Microscope
- Scanning Electron Microscope
- Lighthouse Particle Counter Machine (for Clean Room Environment)
- PPAP
- FAI
- Bore Scope
- Solid Works
- 8D Problem solving Disciplinary
- Six Sigma Green Belt
- ISO 13485, (Medical Devices Quality Management Systems)
- ISO 14971(Risk Management for Medical Devices)
- ISO9001 Series Lead Auditor
Websites
Timeline
Sr. Adv. Manufacturing Engineer
Aerospace Technologies – Honeywell
09.2024 - Current
Senior Quality and Reliability System Engineer
TE Connectivity
04.2023 - 12.2023
Quality Control and Project Management Engineer
Abbott Lab
07.2022 - 03.2023
Quality and Reliability and Validation Engineer
Consolidated Precision Products (CPP)
12.2021 - 06.2022
R&D and Test Application Engineering
3M–Fuel Cell Component Program
12.2014 - 12.2019
R&D Engineer CO2 Sensors and CO2 Recycling Project
3M–Fuel Cell Prog.
12.2013 - 12.2014
Fuel Cell (FC) R&D Application & Quality and Reliability Engineer
3M
06.2001 - 12.2013
Master of Science - Master of International Business (MIB)
Saint Mary’s University
Master of Art - Masters of Business Administration MBA
Istanbul University
Bachelor of Science - Chemistry (Chemist)
Trakya University
Master of Science - Project Management (MSPM)
Saint Mary’s University