Gavin Alcorn
Arvada,CO
Summary
Senior process engineer with expertise in process optimization and cross-functional collaboration. Leveraged lean six sigma methodologies to improve production efficiency and quality assurance. Demonstrated leadership in managing complex projects, consistently delivering innovative solutions on schedule and within budget.
Overview
4
4
years of professional experience
Work History
Senior Process Engineer/Welding Engineer
Fortius Metals
Lafayette, CO
06.2025 - Current
- Led industrialization and scale-up of aluminum wire manufacturing, transitioning processes from development to stable, high-volume production while conforming to AWS quality standards.
- Designed and optimized welding and additive manufacturing procedures for high-performance alloys resulting in improved material properties and reduced production defects.
- Conducted quality assurance (QA) testing on novel in-house welding wire, verifying compliance with industry standards and meeting customer specifications.
- Developed and programmed processes for Laser Directed Energy Deposition and Wire Arc Additive Manufacturing robots, ensuring precise and efficient components for aerospace, defense, and EV.
- Applied Lean Six Sigma methodologies to analyze yield, scrap, and throughput data, conducting root cause investigations and implementing corrective and preventive actions that strengthened process reliability.
- Standardized manufacturing processes through creation of SOPs, control plans, PFMEAs, and work instructions, driving repeatability, risk reduction, and long-term production stability.
- Led cross-functional teams, collaborating with operations, quality, suppliers, and customers to enhance production and drive continuous improvement initiatives.
- Led project milestones and managed timelines independently, delivering complex engineering solutions on schedule and within budget while meeting customer specifications.
Process/Welding Engineer I
Medtronic
Brooklyn Center, MN
06.2022 - 07.2024
- Liaised between internal project managers and laser welding clients, managing bill of materials, timelines, and specifications to ensure seamless communication and transparency.
- Hosted monthly cross-company meetings and weekly check-ins with client project managers, fostering collaboration and ensuring project alignment on >$13M across 26 systems.
- Led team addressing out-of-tolerance fixture issues from a tooling supplier, justifying compliance with tolerance standards, successfully preventing an audit and ensuring continued quality system approval.
- Qualified RSW and Laser equipment through tool qualifications, IQs, and OQ/PQs documentation.
- Tested and collaborated on CAD designs for fixtures to meet design and fabrication requirements for pull testing, scanner mounting, and RSW/laser tooling, improving functionality and efficiency.
- Utilized Principal Component Analysis to engage in discussions on statistical techniques, resulting in real-time statistical prediction programming to detect weld defects.
- Hosted and organized two-day global Medtronic Welding and Joining Summit, coordinating internal and external keynote speakers to share knowledge and breakthroughs in joining technology.
- Managed high-speed cameras to analyze stations and fixtures, identifying inefficiencies and implementing improvements to optimize production processes.
Education
Bachelor of Science - Welding Engineering
The Ohio State University
Columbus, OHSkills
- Process optimization and continuous improvement
- Lean Six Sigma methodology
- Quality assurance and testing
- Project management expertise
- Manufacturing leadership skills
- Supply chain management strategies
- Data analysis techniques
- Cross-functional collaboration
- Statistical analysis proficiency
- Supplier management skills
- Resource allocation strategies
- Risk assessment
Affiliations
Volunteer, A Better Pet LLC - Coach dogs in fulfilling ADA service dog requirements towards psychiatric needs and instructing clients
Timeline
Senior Process Engineer/Welding Engineer
Fortius Metals
06.2025 - Current
Process/Welding Engineer I
Medtronic
06.2022 - 07.2024
Bachelor of Science - Welding Engineering
The Ohio State University