Thomas W. Lewis III

• Company Overview: (One of the leading domestic producers of single use biopsy forceps and polypectomy snares in the US)
• Tasked with leading companywide cost reduction and safety/quality improvement efforts; directed five manufacturing engineers and four technical contributors supporting 150 indirect production employees. Served as liaison for contract manufacturing customers.
• Introduced one-piece flow and Kaizen events to the production floor, increasing volume by 35%.
• Redesigned plant layout to create 25% more space and accommodate five new production cells.
• Participated in 10 new product design efforts and launches.
• Evaluated existing procedures and made proactive adjustments to meet changing demands.
• Participated in development meetings for high-value customers and business operations updates.
• Promoted Design for Manufacturability philosophy.
• Oversaw [Number]-strong team of engineering personnel.

• Company Overview: (Manufacturer of arthroscopic surgical blades, burs, drivers and implants)
• Recruited to manage P&L, $5 million operating budget, and staff of 11 manufacturing engineers and 6 technical contributors supporting 150 indirect production employees. Led companywide safety/quality improvement efforts; implemented future value stream maps in alignment with corporate strategies.
• Reduced COGS by $1 million through insourcing and process improvements utilizing DMAIC tools.
• Improved quality 15%; implemented state-of-the-art one-piece flow concepts across all factories.
• Shortened lead times to facilitate 99% next-day shipping with no production orders on hold >3 days.
• Mentored junior engineers supporting 38 on-time and on-budget new product introductions.
• Performed concurrent design and manufacturing engineering and other functions to reduce time required to bring product to market.
• Reviewed products for compliance with Design for Manufacturing (DFM) requirements.
• Reduced equipment downtime through preventive maintenance and root cause analysis for recurring issues.
• Increased production efficiency by optimizing manufacturing processes and implementing Lean principles.
• Evaluated existing procedures and made proactive adjustments to meet changing demands.
• Oversaw [Number]-strong team of engineering personnel.
• Promoted Design for Manufacturability philosophy.

• Company Overview: (Manufacturer of arthroscopic surgical blades, burs, drivers and implants)
• Managed $2 million operating budget, five manufacturing engineers, a technical team of 4 manufacturing professionals and > 90 indirect production operators. Administered new product and process development, sustaining engineering, and staffing to support >1 million arthroscopy blade assemblies per year.
• Transformed production factory from batch processing to one-piece flow utilizing the TMS philosophies.
• Reduced overall factory footprint and staffing requirement by 15 FTE’s.
• Lowered scrap cost 85% and increased production capacity of the electro discharge machining cells 50%; redesigned device fixtures and evaluated and streamlined overall processes.
• Increased production capacity of the electro discharge machining cells by 50%.
• Specialized Development Processes:
• State of the art laser welding
• Marking of arthroscopic blades
• Electro-chemical grinding/sharpening
• Electro-polish and cleaning
• In-house manufacturing equipment
• In-house tooling design/build efforts (including molded components)
• Coordinated selection of manufacturing methods, fabrication, and operation of product designs.
• Supported business objectives by seeking out new customers and networking at key events.
• Mentored junior engineers, fostering a culture of teamwork and professional growth within the department.
• Developed training programs for new employees, ensuring a skilled workforce with reduced onboarding time.
• Focused on increasing efficiency, lowering cycle times and improving overall quality.
• Evaluated existing procedures and made proactive adjustments to meet changing demands.

• Company Overview: (Manufacturer of arthroscopic surgical blades, burs, drivers and implants)
• Promoted to guide new product design efforts for manufacturability, serviceability, cost, and FDA quality system compliance. Supervised 10 manufacturing engineers, a technical team of 4 manufacturing professionals, and >60 indirect production operators.
• PREVIOUS:
• Six years in the US Navy; organized daily activities for 30 electronics and radar technicians. Managed operations and maintenance budget of >$1 million; held Top Secret Security Clearance and earned three Letters of Commendation.
• Fostered positive and performance-oriented environment by implementing successful reward systems.
• Collected project information and disseminated to appropriate stakeholders.

• Optimized existing designs, reducing production costs and enhancing overall performance.
• Managed multiple projects simultaneously while adhering to strict deadlines and maintaining a high level of attention to detail.
• Brainstormed with product designers to implement and refine new manufacturing processes.

Perform and direct research and development of opto-electronic systems. Establish manufacturing processes for both Department of Energy and commercial units. Collaborate in the design, layout, routing, and manufacturing of prototype circuit boards.

Designed, developed, and manufactured unique 2 color temperature sensor for railroad rolling stock bearings. Design includes detectors, analog components, and optics.

Participated in development of system for non-surgical procedures to perform spectral analysis of biological tissue samples. Includes spectrograph, software, optics, and personal computer.

Planned and managed project budgets of up to $1 million.

Member of Edison Engineering Program

Concurrent Degree Program - Gainesville & Jacksonville, FL

BS Physics & BS Electrical Engineering

Directed the installation, integration, test and support of the shipboard Aegis Weapon System Transmitter Group. Provided liaison between shipyard, Navy, and government contractor staff. Instrumental in lab development of radar modulator decks, high voltage powers supplies, and control circuitry.

Organized daily activities for 30 electronics and radar technicians. Managed operations and maintenance budget of over $1M for 5 radar and computer system work centers. Operated and maintained pulse and continuous wave radar systems consisting of 5 transmitter and 3 receiver subsystems.

• Member of team winning fleet wide missile systems operational competition for 5 successive years.