Garrett Callen

• Led the NPI team in bringing more than 10 products through the NPI process from initial conception all the way through mass production of at least 500 units
• managed a team of 5 engineers and assisted and trained junior engineers in test architecture, manufacturing line design, and root cause/ failure analysis
• Designed, tested, and implemented manufacturing tests using C, Python, and LabVIEW for products at both the PCBA level and at a product level
• Wrote test firmware for specific designs or worked closely with firmware team to create more complex test firmware
• Responsible for architecting and iterating various production lines to meet changing product or customer requirements
• Led DFM efforts of cross functional teams to ensure product scalability and participated in early design reviews of prototypes to maximize product DFM and DFT
• Used SQL to run queries for analytical reports and to validate quality metrics

• Performed root cause analysis on defective PCBAs and products while working closely with the hardware team to implement design improvements and developed corrective actions in the manufacturing processes to prevent reoccurrences

Played a critical role in ramping production of a flagship IOT device from 1,500 units/day to 30,000 units/day by:

• Increasing throughput of a critical PCBA test and validation station by 100% through increases in test yield, cycle time, and streamlining of the test process
• Designed,built,or implemented machines and processes that allowed for rapid parallelization of the production line
• Created quali9ty checks and designed reports to ensure the product met the required standards

Led RMA team responsible for finding and fixing any failures in fleet of IOT devices. Fleet failure rate was decreased from 2.5%/week to less than .3%/week by:

• Performing Root cause analysis on all subsystems of multiple generations of IOT devices. This includes Power, Cellular (3G&4GLTE), Blue-tooth, Camera, and Accelerometer systems. Developed and tested changes, both schematic and firmware, to failed devices
• Resolved any product or maintenance issues by collaborating with Mechanical, Software, Operations teams, as well as external vendors
• Increasing my ability to monitor fleet performance and find any trends in poorly performing devices by learning PostgreSQL

Acted as Test Engineeer of a brand new Blue-tooth product line from conception through mass production by:

• Creating prototype testing and performing assembly, testing, and debug of prototypes
• Using a VNA to do Antenna matching and performing passive antenna measurements with vendors
• Designing and building manufacturing test fixtures
• Writing python test scripts
• Being responsible for FCC testing and certification

• Oversaw production runs of 12 different PCBs.
• Built test fixtures and wrote test programs to streamline the testing process for all circuit boards.
• Created custom hardware such as backplates and heatsinks using Solidworks then managed machine shop fabrication of parts.
• Analyzed modules with the highest probability of failure and created new circuit boards to address those problems.
• Performed both minor and major reworks of 6 different high voltage (>500VDC) PCBs to minimize size and cost while improving functionality.

This was a contract position to design and build cinder-block dehydration facilities on the companies property. This involved :

• Designing all control, heating, and power systems.
• Working with the EPA to insure that all federal and state codes were met and all inspections passed.
• Sourced needed equipment and interfaced with vendors to meet aggressive deadlines.
• Using LabView to control equipment and log all important data.

• Board level design and layout of IOT devices.
• Troubleshooting of various circuits both at the board level and within Linux systems.
• Project lead on multiple alternate power projects for devices. This includes a solar powered backup design and an intermittent power backup.
• Designed and built test fixtures for various circuits and devices.
• Brought multiple projects from conception, through building of prototypes, to mass production (>750 units produced).
• Created custom equipment needed for devices or power systems using Solidworks.
• Wrote assembly documentation for all projects assembled or created by manufacturer.

• Designed and installed all electrical components on 4 different Mechanical engineering projects.
• Selected and implemented motors, relays, motor drivers, microprocessors, signal conditioners, measurement equipment such as DAQ's, thermocouples, pressure sensors, rpm sensors, and torque sensors.
• Designed and built any electronic systems needed for switching, power control, and emergency shutoffs.