DAVID SUTCLIFFE
Durham,NC
Summary
Process automation engineer with expertise in startup, troubleshooting, and equipment development. Proven track record of leading teams to successful project completion over several years. Strong focus on efficiency and innovation in automation processes.
Overview
37
37
years of professional experience
Work History
Principal Automation Engineer
Sutcliffe Enterprises, LLC
Durham, NC
02.2022 - Current
- Working as a 1099 contractor, I support clients with their automation needs.
- As an alternative to in-house staff, I provide cost-effective, efficient, technical services on an as-needed basis.
- Clients are equipment OEMs and end users in a variety of industries, including pharma, personal care, heat treatment, automotive, and biotechnology.
Process Automation Engineer
Pendergraph Machines
Durham, NC
07.2018 - 01.2022
- Working in an equipment OEM design and manufacturing environment, responsible for the integration and programming of PLCs, HMIs, and peripheral devices. Experience with Allen-Bradley PLCs, various HMIs, servo motors, VFDs, safety controllers, vision systems, Ethernet interconnectivity, and remote access.
- Clients included pharmaceutical, life sciences, cosmetics, and consumer care products. Production rates of up to 5 units per second.
Senior Manufacturing Engineer
GKN Driveline
Mebane, NC
02.2014 - 07.2018
- Resolved production engineering problems related to product design or performance issues by working closely with other departments such as Quality Control or Design Department.
- Evaluated existing procedures for possible automation opportunities that could reduce manual labor needs while increasing throughput capacity.
- Performed root cause analysis on defective parts and developed corrective actions to prevent reoccurrence.
- Created technical drawings using CAD software based on product designs.
Manufacturing Engineering Manager (Automatic Transmissions)
AW NORTH CAROLINA, INC
Durham, NC
02.2003 - 02.2014
- Managed a team of 11 manufacturing engineers, fostering continuous development and providing technical support.
- Directed cross-functional teams to enhance production line efficiency and effectiveness.
Supported engineering initiatives in automatic transmission production, focusing on aluminum and steel machining. - Launched new product lines by optimizing equipment and layouts to meet capacity requirements.
Manufacturing Engineer (Torque Converters)
AW NORTH CAROLINA, INC
Durham, NC
09.2002 - 02.2003
- Provided engineering support for daily operational issues, ensuring efficient workflow.
- Adjusted machining, welding, and testing processes to enhance productivity.
- Applied Toyota Production System principles to identify and address constraints.
- Investigated root causes of quality issues using 8D methodology and implemented effective countermeasures.
Manufacturing Development Manager (Propshafts)
GKN AUTOMOTIVE, INC
Mebane, North Carolina
03.2000 - 09.2002
- Managed process development, benchmarking, and standardization for passenger car and light truck propshafts.
- Analyzed cost, manufacturability, and weight/balance performance of various propshaft configurations.
- Evaluated new welding processes, including magnetic arc, laser, friction, GMAW, and plasmatron.
- Led international workshops to establish competitive manufacturing strategies for propshaft production.
Advanced Manufacturing Engineer (Shaft Assembly Processes)
GKN AUTOMOTIVE, INC
Durham, NC
03.1998 - 03.2000
- Facilitated transfer of propshaft assembly to new facility in Columbia, SC.
- Trained local staff on equipment use and maintenance to enhance productivity.
- Assisted with quality concerns leading to significant improvements.
- Designed assembly cell, achieving 25% reduction in costs compared to similar cells.
- Developed assembly cell for three-piece propshaft, completed within six months and $1.6M budget.
- Represented GKNAI at international workshops, influencing design of joint/shaft interfaces and sealing systems.
International Leadership Development Program
GKN GROUP SERVICES
Redditch, UK
08.1995 - 03.1998
- Leveraged hands-on experience and formal education to address four graduate-level challenges at GKN group.
- Designed and launched telephone kiosk assembly line within two months.
- Reintroduced re-manufactured overdrive units to classic car market.
- Facilitated 'Problem Solving Teams' in halfshaft factory in Italy to enhance productivity.
- Tested aircraft systems on new and overhauled military helicopters as Flight Test Engineer.
Engineering Apprentice
GKN WESTLAND HELICOPTERS
Yeovil, UK
09.1988 - 09.1992
- Completed ENTRA accredited technical apprenticeship with leading defense helicopter manufacturer.
- Developed practical skills in helicopter transmission manufacturing and assembly over four years.
Conducted assembly of aircraft components, including SAAB engine nacelles and helicopter airframes. - Manufactured and tested composite rotor blades for performance and safety standards.
Executed development of composite material applications for aircraft floor structure design. - Designed tooling and gauges for gearbox component gear manufacturing.
- Led project for manufacturing cell of aircraft landing gear pins, ensuring quality and efficiency.
Education
Bachelor's Degree - Manufacturing Systems Engineering
University of Hertfordshire
Hatfield, Hertfordshire, UKAssociate Degree - Mechanical & Production Engineering
Yeovil Technical College
Yeovil, Somerset, UKSkills
- PLC programming
- HMI design
- System integration
- Project management
- Mechanical design
- Process improvement
- Quality control
- Lean manufacturing
- Root cause analysis
Affiliations
- Registered with the UK Engineering Council as a Chartered Engineer
- Member of the Institute of Engineering & Technology, UK
References
References available upon request.
Timeline
Principal Automation Engineer
Sutcliffe Enterprises, LLC
02.2022 - Current
Process Automation Engineer
Pendergraph Machines
07.2018 - 01.2022
Senior Manufacturing Engineer
GKN Driveline
02.2014 - 07.2018
Manufacturing Engineering Manager (Automatic Transmissions)
AW NORTH CAROLINA, INC
02.2003 - 02.2014
Manufacturing Engineer (Torque Converters)
AW NORTH CAROLINA, INC
09.2002 - 02.2003
Manufacturing Development Manager (Propshafts)
GKN AUTOMOTIVE, INC
03.2000 - 09.2002
Advanced Manufacturing Engineer (Shaft Assembly Processes)
GKN AUTOMOTIVE, INC
03.1998 - 03.2000
International Leadership Development Program
GKN GROUP SERVICES
08.1995 - 03.1998
Engineering Apprentice
GKN WESTLAND HELICOPTERS
09.1988 - 09.1992
Bachelor's Degree - Manufacturing Systems Engineering
University of Hertfordshire
Associate Degree - Mechanical & Production Engineering
Yeovil Technical College
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