Simeon Atanasov

Design new manufacturing processes and retrofit existing ones to support the digital manufacturing transformation. This involves identifying opportunities for automation, data collection and analysis, and integrating new technologies to improve efficiency, reduce waste, and enhance product quality.

Projects 2021-2023:

• Production Release of fully automated assembly line (March 2021-March 2022)

Company: Flex (contract manufacturing of Abbot), Product: FreeStyle Libre, Role: Automation /Manufacturing engineer

• Scale existing manufacturing capacities by implementing fully automated mass balancing process (February of 2022-Present)

Company: ChronosImaging, Product: CT X-ray tubes, Role: Project Technical Lead

• Health Monitoring Devises Product Development Platform (October 2021-Present)

Company: Bionety LLC, Product: Product Development Platform Health Monitoring, Role: Platform Architect / Cofounder

• Manufacturer of 100K products for industrial, automotive, aerospace, consumer, medical, and telecommunications.
• Lead development of projects, assess risks and drove process improvement initiatives while analyzing manufacturing costs and strategically planning new manufacturing techniques. Manage diverse range of manufacturing projects, from basic manual assembly processes to advanced automated, high-volume processes. Collaborate on planning, procurement, and development of tools and equipment required for each project. Establish and implement procedures and processes necessary for the efficient and effective production of new products.
• Identified opportunities for improvement in existing cable assembly processes and provided solutions that drove a 20% increase in throughput and a yield improvement of over 90%. This resulted in a boost in revenue of $300K annually.
• Strategized a fully automated cable assembly system for 3 to 5-pin cable harness assemblies, consisting of over 200-part numbers. Facilitated process flow development, process simulation and optimization, equipment specification and requirement development, and vendor procurement activities. This resulted in an estimated annual cost savings of $850K, significantly reduced cycle time, and a drastic decrease in non-conforming products
• Participated in the product development of the Molex ArcArrest 30A Switch-Rated Connector system and then implemented a cost-effective manufacturing assembly operation. This resulted in an annual projected revenue of $2.4 million. Additionally, ensured flawless process lunch at the Molex manufacturing facility in Juarez, Mexico.
• Developed and released a wire termination process for John Deere commercial vehicle applications, utilizing the Telsonic ultrasound torsion welder. This replaced the conventional crimping operation, winning a customer project with an annual revenue of $10 million.
• Challenged the existing product development processes and promoted new, optimized product/process verification and validation protocols utilizing the Design of Experiments (DOE) methodology. Implementing the new test protocols resulted in a cost savings of $120,000 annually due to a significant reduction in sample size and testing cycle times.

Manufacturer of CT scanner x-ray tubes for Philips, Siemens, GE, and Toshiba scanners.

• Identified, analyzed, and executed cost reduction initiatives, cycle time improvements, and Lean Manufacturing methodologies that effectively improved the product cost structure on existing anode assembly lines, resulting in $230,000 in annual savings.

• Addressed legacy noise and vibration specifications for a product, which resulted in a poor yield of 82%, equating to a loss of $330,000 annually. Conducted systematic failure analysis and comprehensive risk assessment to propose and implement optimized specifications that improved yield to 98.7%.

• Developed and Implemented an industry-first, fully automated, and dynamic balance process for x-ray tube anodes, resulting in increased yield, quality, and reliability across four product lines. This process also reduced the cycle time requirements by almost one-tenth of the previous time.

• Developed and introduced an automated shaft-to-rotor press interference system that featured a highly complex and precise process while maintaining the required high level of cleanliness. This system was adopted across organizations, resulting in a year-over-year revenue increase of over $20 million.

• Designed and implemented a fully automated pre-screening test system for audible noise and vibration of products to detect potential bearing failure modes. This implementation saved the company $250K annually by preventing the production of non-conforming products and significantly reducing warranty costs.

• Facilitated and conducted training and mentoring programs for new engineers, promoting problem-solving methodologies, sharing knowledge initiatives, and introducing breakthrough technologies.

• Introduced and designed an implementation plan for Lean principles to be applied across production and leadership

• Led Six Sigma projects addressing yield improvement initiatives and premature product failures in the field