Thomas Gallagher

Evaluate new products to estimate and confirm variable costs, target efficiency and projected yield.

Developed new process for onboarding new products/customers for seamless integration into production ensuring that company expectations for quality, safety and variable costs are met.

Identify root causes for issues impacting new product.

Performed Kaizens events utilizing PDCA tools for root cause analysis and identifying corrective actions for process inefficiencies including:

• New vinyl scrap program reducing material waste by 18%
• Redesign of high mix production line improving throughput by 45% with existing labor
• Developed new process for boneyard units, batching units for production and glass remakes driving OTIF from 75% to 98%
• Revamped EOL window packaging system resulting in over $100,000 savings annually.

Value stream mapping all processes in AutoCAD for optimization of future state production
Spec'd, validated, installed and trained operators/maintenance on new machines including 5 axis CNC workcenters, automated hot plate welders and pneumatic presses in addition to designing and building workstations for production lines
Worked with Operations to establish and document standard work for all new and existing processes

Facilitated continuous improvement projects driven by pareto’s of key quality metrics resulting in FPY increase to 95% and reduction of warranty/RMA requests by 15%. Projects included:

• Upgraded spacer system allowing for even compression when installing glass to reduce stress cracks
• Creation of jigs/fixtures to reduce variability during hardware assembly
• Redesigned final out tables to avoid silicone vinyl contamination and other surface.
• Upgraded packaging to prevent damages to sensitive components like glass and screens

Perform root cause analysis and corrective actions for manufacturing defects. Perform Quality
validation by completing PPAPs, PFMEAs and control plans for new products and processes.
Manage all non-conforming product, corrective actions, quality document revisions and engineering
change orders through SQMS.

Support senior engineering in development of line layouts to maximize line efficiency.
Identify and justify new tooling and equipment to increase productivity and/or mitigate safety risks
in existing processes.
Design and prototype jigs, gages and similar tooling to reduce variability in manufacturing
processes.