Dan Mora

• Responsibilities: Lead engineering team to launch new products and support post forming CNC machining operations while instilling Toyota Kata coaching method
• Experience:
• Led team to develop streamlined approach to cost savings, 3D top down design and PDM file management
• Standardized design flow, instill best design practices and apply “Find a way” & “How can we” approaches to problem solving
• Facilitate cross functional product “Safe launch” scope of work, work breakdown structure, and timeline for $1MM+ capital equipment projects
• Facilitate forecasted consumable tooling demand between tool integrator and manufacturing teams on cutting tool usage predictions that saved $250K+ annually by ordering at higher volumes 3-6 months in advance
• Launch full line of underground mining products accounting for $2.49MM in annual sales
• Facilitated new product and new market launch with projected sales of $2.4M annually.
• Production capacity expansion in growing market segments $2.4MM in annual sales
• Evaluated project requirements to identify and mitigate risks.
• Addressed design challenges and evaluated alternative design models to meet project requirements.
• Coordinated engineering team for projects in commercial and industrial development.
• Managed design and manufacturing teams to build proprietary process equipment within aggressive cost and time constraints.
• Coordinated selection of manufacturing methods, fabrication, and operation of product designs.
• Instilled Toyota Kata methodology to reduce cycle time and meet target margins.
• Evaluated existing procedures and made proactive adjustments to meet changing demands.

• Responsibilities: New Product introduction, Secondary operation support, New process introductions and be the Voice of the customer to the production floor
• Experience:
• 0129004, 0129008, 1594002 new pick & place SMED escapement design
• 3D printed for low cost validation
• First ever 3D Top down design used in production.
• First ever 3D printed multi-material build used in production 3DP carbon fiber infused nylon and 3DP stainless steel.
• 3D printed hardened steel cold forming inserts to reduce project timelines
• Automatic coolant make-up system for Kitako CNC machines ~ $40K/Yr
• Successful expanded SMED escapement design to: 0173, 0194, 0105 & 1342.
• Automated Compact thread detection device

• Responsibilities: New product introduction, Pultrusion profile design for step and extension ladders, pultrusion material qualifications, root cause analysis
• Experience:
• PE catalyst packages qualification to prevent ~$2-3MM in lost production due to hurricane outage
• PE low temp catalyst qualification to prevent ~$1-2MM in lost production due supply shortage
• Led qualification testing and implementation of new FRP raw materials sources.
• Streamline qualification test procedures to improve the products time to market.
• Designed and qualified new pultrusion profiles for front end projects (5 total - ext. Step)
• Continuous improvement: expanded market opportunity & global footprint with new thermoset resins including: epoxy, vinyl ester, urethane, polyester and resin blends.
• Added patented value to key components for Aluminum and FRP ext. Ladder models
• Specialty ladder model upgrades and performance improvements
• Patents: 16 total patent application filings and 5 granted
• Design patents: 4 - Extension ladder end cap (2017)
• Utility Patents: End cap design (2017), Ladder foot design (2016), Rung design (2016), Compact in-board Leveler design (2016), Ladder rail features (2016), Top design 1 (2016), Top design 2 (2016), End cap design (2016), Rivet design (2016), High Strength Riveting process (2016), Carbon fiber rung design (2014)
• Products released:
• Patented riveting technology - 50% more joint strength
• Reduced product cost, Increased process speeds and machine capacity over 150%
• DP357 "Switchback" ext./step dual purpose aluminum ladder - $2MM sales in year 1
• 2016 NCAA net cutting FRP podium ladder (Advertising and Marketing design)
• PS-48 (MK06) steel Mini Scaffold $250K - $400K sales annually
• MT1-13, MT1-17, MT1-22 lightweight AL Multi ladders - $2MM sales for one time promo
• 1A & 1AA "Lightweight Performance" FRP ext
• Ladders (3 New Pultrusion profile) - $2.5MM in sales

• Conduct Design reviews regarding new design challenges with the Change Control Board then implement changes at factory floor
• Evaluate defective shop floor parts and recommend rework instructions vs scrapExperience:
• GEB15 AC traction motor new PE bearing design, Created new GMG206/209 Alternator repair specification
• GEB29 AC drill motor shipping shock test evaluation, Bolted Joint calculations for GE725 DC brush holder

• Update Maintenance Instructions, work-scopes, and Rx’s to provide correct field documentation
• Provide weekly Reliability Trotter Matrix and Score Card for reliability teamExperience:
• Updated CML Troubleshooting guide with new shop protocol
• Poka Yoke New Loco turbo labyrinth seal test procedure
• Pre-shipment testing (B26) UK Locomotives
• Blue Flag training

Member – Pultrusion Industry Council, 2018-Present, Society of Automotive Engineers, Mini Baja Project, 2002-2003, Society of Automotive Engineers, Mini Baja Project, 2002-2003 - Designed swing arm assembly, rear braking assembly, and drive train.

President - Society of Automotive Engineers, Mini Baja Project, 2001-2002

Personal Activities - DJ-ing, Weight Lifting, Rock Climbing, Snowboarding, and Water Skiing

Cancer fundraising Event – DJ’ed at Cancer fundraising event, April 2010

Books Read - Discover Your True North - Bill George, Never Split the Difference - Chris Voss, Trump: The Art of the Deal - Donald J. Trump, Toyota Kata - Mike Rother