TIMOTHY BARNES
WESTMINSTER,MA
Summary
Dynamic Development Engineer and CNC Manager/Programmer with extensive experience at ITW and Novolex, recognized for optimizing product lines and manufacturing efficiency through Lean manufacturing principles and effective project management. Achievements include a 40% reduction in costs and improved production times by pioneering innovative technologies and methodologies, while maintaining a strong focus on customer needs assessment and supplier management.
Overview
28
28
years of professional experience
Work History
DEVELOPMENT ENGINEER
Novolex
10.2022 - 10.2024
- Evaluated new plastic resins for product line enhancement by conducting compatibility tests, mechanical testing, and chemical analysis
- Implemented studies to optimize formulations for performance, cost, and environmental standards
- Oversaw new product development
- Project Managed new biodegradable resins for cutlery, creating supplier testing plans to validate materials for potential inclusion in Novolex's product lines
- Program-managed introduction of a new Mucell system, incorporating nitrogen gas during injection, established a new product line, and reduced plastic usage
- Successfully integrated a manufacturing method in the onsite toolroom and enabled efficient production of mold components
- This approach reduced lead time by 75% and cut costs by 40%, allowing for timely and cost-effective manufacturing
- Assuming 35% of manufacturing engineering responsibilities for production floor equipment
- Overhauled a pad printing machine, reducing scrap rates from 60% to 3%, and removed dependency on external print services
- Conducted failure analysis and root cause identification for manufacturing equipment issues
- Implemented process improvements in injection molding to increase efficiency and reduce cycle times
- Integrated mold venting standards to expand the processing windows, reduce down cavitation, and improve cycle times, reducing cleaning schedules from 3 times to once every 24 hours
PRINCIPAL PRODUCT DESIGN ENGINEER
ITW
04.2007 - 03.2017
- Company Overview: Tier 1 supplier for the automotive industry
- Served as a global subject matter expert for cabin pressure relief valves, leveraging extensive experience working globally with GM, Ford, FCA, and Toyota to provide technical guidance and support
- Led the design of new Pressure Relief Valves (PRVs) for various automotive manufacturers, ensuring all designs met stringent customer requirements
- Managed the complete design process, including testing and validation, collaborating with manufacturing engineering teams for initial vehicle trials, often held on-site
- Enhanced ITW's standing within Ford by increasing the company's PRV fulfillment rate from 62% to 84%
- Innovative designs that reduced mold cleaning cycles from 3 to 4 days to just 1.5 days, improving production efficiency
- Collaborated with ITW's core development team in the creation of new products to solve critical automotive industry needs
- Served as the ITW contact lead for GM, presenting advanced design concepts, and showcasing ITW's forward-thinking approach to PRV technology
- Tier 1 supplier for the automotive industry
CNC Manager/Programmer
ITW
02.1997 - 03.2007
- Company Overview: Tier 1 supplier for the automotive industry.
- CNC Department Manager with extensive experience leading teams and optimizing operations.
- Streamlined toolroom workflows by implementing Cell concept and directing $750K investment to establish high-speed milling and electrode departments, significantly enhancing precision, capacity, and productivity.
- Proficient in Unigraphics NX for precise design, 3D electrode modeling, CNC programming, and high-speed hardness steel milling with tight tolerances.
Education
Some College (No Degree) - Computer Science
Mount Wachusett Community College
Gardner, MASkills
- Lean manufacturing
- Design for manufacturability
- Cad/CAM NX 11
- Proficient in SolidWorks
- Quality Assurance Testing
- Root Cause Analysis
- Continuous improvement
- Project management
- Customer needs assessment
- Mold maker
- 3D printing techniques
- Prototyping techniques
- Rapid prototyping
- Fixture design
- Presentation and communication
- Supplier management
Timeline
DEVELOPMENT ENGINEER
Novolex
10.2022 - 10.2024
PRINCIPAL PRODUCT DESIGN ENGINEER
ITW
04.2007 - 03.2017
CNC Manager/Programmer
ITW
02.1997 - 03.2007
Some College (No Degree) - Computer Science
Mount Wachusett Community College
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