Dimitri Tsaousis

- Started from scratch to create UL 891 Switchboard department

- Created mechanical engineering department

- Created inventory control and part number tracking system, translated to Cin 7

- Created quality control department

- Established best practices and created faux ISO 9001 system ( in process of being certified to ISO)

- Created assembly department

- Created various jigs, tooling, and fixtures for assembly.

- Set assembly best practices and standards

- Created intricate and detailed inspection procedures and documentation

- developed traceable metrics for all operations at the facility

- Used AI to create a monitoring interface to detect manufacturing bottlenecks and slow downs

- Worker with sales to establish new customer base

- Attended trade shows and had high level conversations with many C level members or various companies

- Developed supply chains for various components both internationally and domestic

- set up machining and fabricating shops overseas to assist other product lines

• Developed mechanical engineering department from the ground up
• Developed quality department from the ground up
• Developed quality department from the ground up
• Spec’d out and ordered equipment and tooling
• develop led inventory management systems
• Helped develop manufacturing management and tracking systems
• Acquired more engineers and staff to support growth
• Mentored engineers, both young and old, in manufacturing principles for each work center
• Developed workcenter specific engineering practices ( laser, brake press, stamping machines, machining centers)
• Developed engineering practices and standards to comply with various UL requirements and standards
• Led multiple multi-switchboard design projects
• Enhanced product quality with knowledge of sheet metal and product development from past work
• Secured vendors in Colorado from past connections to assist in manufacturing
• Took company from 1 switchboard to over 30 in the first year
• Took company from making 50 parts a month with very high scrap rate to over 5000 parts a month with less than 3% scrap rate
• Standardized switchboard development through ABB extension programs
• Reduced design cycles from months to weeks
• Reduced scrap output and failures at multiple work centers
• Developed manufacturing tolerances and quality sampling rates
• Developed configuration programs to create standard designs quickly- Some as low as 9 minutes even with several hundred parts
• Instituted GD&T practices for designing and print creation
• Created part numbering systems for both stocked and custom components
• Created Engineering Print guidelines tune with our manufacturing capabilities
• Worked with the submittal teams to translate project requirements to engineering teams
• Worked with manufacturing teams to establish best engineering practices tuned to our manufacturing capabilities
• Designed new product lines to compete with legacy manufacturers
• Designed tooling and texturing for assembly
• Designed assembly processes and standardized reporting on the process
• Developed highly specialized fixtures for assembly

Started a product development company to assist in manufacturing and product development for many industries

- Worked with customers to establish scopes of work, develop ideas to be manufacturable, and lower product cost

- Worked with vendors to achieve quality and material specifications for various industries

- Worked with local and international manufacturing facilities to create supply chains for customers

-helped create fixtures and tooling for large scale products ( Automotive, railroad, and agriculture)

Industries include:

-railroad

-automotive

-agricultural

-consumer products

-electronics

• Worked on sustaining pre-existing legacy designs and machines
• Developed guarding and accessory pieces for existing machines
• Work within strict FDA guidelines and requirements to achieve design requirements
• Completed R&D work on next generation machines
• Established product wide retrofits and replacements across multiple subsidiaries
• Approved alternative components for legacy designs
• Led a feasibility study on the next generation of machines
• Developed budgets and timelines for projects
• Developed high specialized tooling and fixtures for assembly
• Set up multiple large scale facilities for Apple, tuna, and peach processing
• Managed multiple projects within multiple product subsidiaries
• Work with multiple subsidiary product owners to collect project specifications and requirements and translate these to engineering teams
• Managed multiple engineering teams across multiple product lines
• Redesigned components for ease of manufacturing and assembly
• Work with outside manufacturing facilities to create supply chains
• Travel overseas to install prototype and first production machines and collect data to improve or validate designs

• Developed over 300 individual products across multiple industries for multiple companies
• Assisted in quality control and process development
• Created process documentation for both manufacturing and assembly
• Created quality and process systems for all manufacturing projects
• Worked within strict automotive, medical device, and defense standards to assist in legacy manufacturing updates and design changes ( ISO 9001)
• Completed various design for manufacturing and design for assembly studies on multiple products across multiple industries
• Established and worked within ISO quality systems
• Developed PDM standards and naming conventions for all products
• Designed, manufactured, and built various automated machines for the shop
• Machines included: Induction heating machines for pre-heating metal to be formed, automated grinding machines for Aerospace components, Small part/screw sorting, counting, and bagging machines, etc
• Designed and programmed various robotic welding projects
• Supported robotic welding cells with part and consumable inventories
• Set up supply chains for robotic welding cell projects
• Troubleshooted robotic welding cells
• Created complex and extremely specific fixturing and tooling for assembly process of tightly controlled aerospace assemblies ( defense, satellite)
• Worked with customers to collect specifications and requirements for product development
• Worked with the in-house tooling design and manufacturing shop to create stamping tools for large volume runs
• Worked with various vendors and suppliers to acquire quality certifications for materials and components
• Worked on and designed for various stamping machines ranging from 45 tons to over 260 tons

• Designed multiple Fall protection devices
• Worked within strict standards for Fall Protection devices
• Established supply chains for new and existing products
• Completed various R&D projects using bleeding edge technologies and materials
• Attained a patent on designed items
• Patent #: US9611664B2
• Assisted in multiple patented designs

• Responsible for various automated machine designs
• Wrote code to control various projects in multiple languages
• Worked within strict FDA guidelines and requirements for Pharmaceutical machines
• Assisted in various automated projects