Mechanical Engineering Manager, Corporate Projects at Amazon
April 2014 - Present
• Developed requirements and specifications for the launch of several new (unannounced) projects.
• Helped to build new product development group from scratch, including establishment of new support teams, setup of manufacturing partners both domestic and overseas, and development of formal product development cycle for a new group in Seattle.
• Delivered representative prototypes and iterated toward manufacturing ready products that meet aggressive technical specifications developed in conjunction with software partners.
• In addition to technical leadership and individual contributor work, hired and managed a team of 9 hardware development engineers in support of mechanical design and all peripheral manufacturing and testing functions for 5 different products.
Senior DfX Technologist at Microsoft
2014 - 2014
Used skills in measurement and data analysis to design and execute experiments (DOE) to establish key factors for improvement of quality in key optical elements and systems.
DfX Design for Assembly Engineering Lead at Microsoft
2009 - 2014
o Used Six Sigma, DOE, statistical analysis, and other problem solving techniques to solve critical design and process issues, saving over $18M with my Green Belt and Black Belt projects.
o Worked closely with optical engineers to optimize design and tolerance budgets for mechanical mounting of optical components, improving yields, reliability, and performance.
o Traveled to China, Taiwan, and Israel to oversee manufacturing and supplier quality, resulting in timely delivery of product builds leading to verification of readiness for mass production.
o Designed fixtures, assembly process, and thermals for Kinect, which sold 8 million units in 60 days, as well as Kinect 2.0.
o Reviewed product from DfA perspective and drove design modifications with key stakeholders in multiple product lines, offering solutions that reduced part count (-10%), optimized assembly flow, reduced headcount (-15%), reduced fasteners, added poka-yoke features, and increased tolerances.
o Conducted experiments (DOE) and other testing to prove robust design and optimize process parameters.
o Worked extensively with Compliance team to create EMC/ESD mitigations that meshed easily with product design and assembly process.
Mechanical Engineer at Microsoft
2007 - 2009
Modeled PC subsystem in FloTHERM, providing more informed decisions about thermal design.
Created FEA models using ANSYS/Workbench and Pro/Mechanica that drove decisions about mechanical design tradeoffs in sheetmetal and plastic parts.
Outsourced FEA using LS-DYNA with Indian firm, establishing product drop specification.
Designed and modified parts and assemblies using Pro/Engineer while following DFx guidelines, resulting in a more manufacturable, serviceable, and reliable product.
Held design reviews and design proposal meetings to keep management and team members informed.
Directed contingent staff, technicians, and manufacturing resources in order to complete design, testing, quality, and supply chain tasks and deliver prototype and production builds on schedule.
Documented the product with new part numbers, descriptions, detail drawings, and Bills of Material for over 300 parts and over 60 sub-assemblies.
Traveled to China and Taiwan to oversee quality control, manufacturing, and supplier quality, resulting in timely delivery of 4 product builds leading to verification of readiness for mass production.
Mechanical Engineer at RB Carr Engineering
2006 - 2007
Designed and detailed mechanical components using Solidworks to facilitate design improvements that increased usability and customer satisfaction.
Tested and troubleshooted centrifuge operation, drawing out bugs and creating a more robust design.
Performed FEA using COSMOS in order to ensure product safety under specified operating conditions.
Developed processes and databases to control assembly drawings and BOMs as well as manage inventory for the manufacturing floor, resulting in an efficient, streamlined manufacturing environment.
Managed and assigned project tasks and deliverables across multiple disciplines, enabling a development process that met product benchmarks and deadlines.
Mechanical Engineer at Bleck Design Group
2006 - 2006
Created award winning designs for packaging of electro-mechanical components by using advanced surfacing CAD techniques in Pro/E to create 3D models that matched industrial design intent.
Designed parts with stamped sheet metal, injection molded plastics, thermoforming, and metal casting to meet customer needs and cost targets.
Mechanical Engineer at Xerox
2003 - 2005
Brainstormed and created Pro/E and working prototype models of printer functionality that proved design viability before completion of final design.
Tested new designs to assure compliance with standard life cycles under full range of stacked tolerances, using DOE and Shainin techniques to accomplish thorough testing and failure analysis.
Worked with buyers, quality & manufacturing engineers to ensure low cost, manufacturable part design.
Used Design for Manufacturability techniques to ensure designs were robust and easily manufactured.
Developed flow charts and diagrams and met with design review teams to work out system interfaces, resulting in sub-assemblies that meshed together without problems. Documented the process in written design reports and presentations for design reviews with management and manufacturing.
Worked with EMC/EMI and Vibration test engineers to ensure designs were compliant with regulations and would not be adversely affected by harsh overseas shipping conditions.
Worked with overseas engineers on manufacturability and design issues, resulting in clear, robust assembly procedures in place before production ramp.
Ink Research and Development Intern Contract from August 2003â April 2004
Collaborated with Chemical Engineers and utilized in-house model shop to design fixtures for testing physical properties of new solid inks.
Developed tests to directly compare ink performance characteristics in a quantifiable manner.
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