Terence O’Neil Jr

• Led cross-functional team supporting R&D, manufacturing, and sustaining engineering for high-performance plasma systems.
• Fostered a quality-driven, high-engagement culture (96.7% approval) and implemented safety protocols that reduced workplace incidents.
• Delegated tasks strategically to optimize team strengths and close knowledge gaps; mentored junior engineers to build technical depth.
• Drove root cause analysis and corrective actions for complex technical issues, improving product reliability and reducing warranty claims.
• Sponsored quality-focused redesigns (coolant systems, torch components, consoles), extending product life and enhancing performance.
• Co-Project manager on 9235 XPR460 Project
• Sponsored the XPR Rotational Sleeve project, achieving a 10× durability improvement through design and material optimization.
• Improved lab operations by introducing a Lead Technician role and structured weekly standup's for task and resource allocation
• Collaborated with commercial teams to deliver customer-focused engineering solutions that supported revenue growth.
• Justified and hired additional engineering resources to expand sustaining capacity and reinforce quality oversight.
• Facilitated strategic talent movement, importing specialized skills and exporting internal talent to key roles across the organization to strengthen engineering and quality capabilities.

Heavy Industrial Plasma Systems

• Led technical operations and cross-functional teams across torch assembly, kitting, and outsourced manufacturing, supporting new product introductions and sustaining engineering.
• Drove major quality improvements, reducing scrap by over $550K annually and customer feedback rates by 95% through Lean Six Sigma Green Belt projects and process redesigns.
• Spearheaded multiple capital equipment implementations (e.g., Mori Seiki NLX, Rofin Fiber Laser, Promess Servo Press, Servo Potting System) to modernize manufacturing capabilities.
• Launched key product lines including HyPro2000, MaxPro200, and XPR Torch systems, overseeing design, testing, and release of torches, receptacles, and consumable kits.
• Implemented electronic assembly record systems and standardized rework processes to improve traceability and operational efficiency.
• Mentored junior engineers and interns, and created new roles (e.g., Manufacturing Operations Specialist) to strengthen team structure and support.
• Collaborated with suppliers and commodity managers to resolve quality issues and implement print changes for outsourced components.
• Contributed to product design language and led DOE testing for new technologies such as the XPR Torch “Quick Lock” system.
• Promoted Design for Manufacturability philosophy.
• Developed and maintained relationships with suppliers to facilitate quality and timely delivery of materials.
• Improved equipment reliability through preventive maintenance programs and operator training initiatives.

Facility Sales: $90M/year

• Provided technical support for CNC ‘Hard Turn’ and Ring Finishing Cell equipment, including CNC Grind and CNC Lathe operations.
• Developed CNC (CAM) programs and optimized tooling, grinding wheels, CBN inserts, jigs, and fixtures.
• Led capital projects including the implementation of Okuma V60R Vertical Lathe and Magnetic Chuck Technology.
• Designed and implemented advanced multi-surface ‘Hard Turn’ processes, improving quality and efficiency.
• Collaborated with suppliers and commodity managers to resolve quality issues and update engineering prints.
• Spearheaded initiatives to reduce setup time by 50–75% through tooling standardization and process improvements.
• Reduced tooling costs by 25% via insert management systems and material-grade standardization.
• Promoted Design for Manufacturability (DFM) principles across cross-functional teams to accelerate product development.
• Managed end-to-end capital projects, ensuring on-time delivery and budget adherence.