Portfolio

This is a Beta-release of my portfolio.  It is, by no means, complete and will be upgraded and modified moving forward.  But I am “putting it out there” to hopefully get some attention for my job search…  comments and additions welcomed.

 

As you can imagine, these are snapshots of projects I’ve done, and are by no means a comprehensive sweep of my career*.  Rather, they’re projects I’ve done where I’ve been fortunate enough to be able to cobble together enough to put out a “SPAR Sheet” or write an essay about it.

Also note: There is no confidential or proprietary information here.  All these products are either on the market, have been “sanitized” to the best of my “good faith” ability to eliminate confidential information, or were never implemented.  Most CAD model pictures are mock-ups , i.e., concepts to show the desired information, and nothing more.

* Note: I spent six years at Cabot Corporation; being bound by a stringent NDA, there is very little I can say about my experiences there as virtually everything I did there is proprietary.  A pity – I’ve got some good stuff from there.

US PATENTS

6059483: Sealed joint for a multi-component injection molded automotive lamp assembly.

6395201: Method and manufacturing an automotive reflector.

Not patented yet, but published: A Method For Producing Carbon Black Using An Extender Fluid.

DESIGN AND ANALYSIS

 

DESIGN FOR MANUFACTURING AND ASSEMBLY

 

VALUE ANALYSIS / VALUE ENGINEERING & COST REDUCTION

 

PROCESS DEVELOPMENT AND PROBLEM SOLVING

 

PROJECT MANAGEMENT & BUSINESS SKILLS

 

ENGINEERING-RELATED ESSAYS ON MY BLOG

Engineering Change Orders – Thoughts on the ECO process and capturing more information in it.

The Value of Analysis (Part I) – Case study of value analysis sessions to reduce costs.

The Value of Analysis (Part II) – Case study of value analysis and the importance of competitive benchmarking.

Fix the Problem I: Eliminate Variability, or Adapt to It – Case study of identifying where variation in a process comes from, and how to handle it.

Fix the Problem II: Medical Blister-Pack Punctures – Case study of finding the location of where a customer-found problem originated, and some proposed solutions.

Fix the Problem III: Ink Adhesion to Plastics – Case study about adhesion to plastics, and how it was solved.

Fix the Problem IV: Water Ingestion into a Headlight – Case study examining a problem at an OEM customer.

Fix the Problem V: Cultural Awareness is Critical – Case study of how an understanding of Japanese culture avoided costing people face.

Case Study: Choosing Plastics for a LEGO Toy Truck – Case study about how to select plastics for an application from my career.

Design for Assembly: A Child Sippy-Cup Cap – Case study of a DFA problem showing how partial symmetry can be a problem.

Fix the Problem VI -The Role of Material Microstructure in an Overmolding Application

Choosing Plastics – Why it’s important to think of the end goal – minimized part cost – and not obsess over price per pound of resin pellets.

Visiting Suppliers – Three examples of why visiting suppliers, whether prospective, established, or best-in-class, is a very good idea.

Fix the Problem VII: Product Launch Crisis – Case study about a product launch going particularly badly, and how we worked to identify the critical areas to focus attention.

Fix the Problem VIII: The Problem Toggle – Two examples of solving a problem by truly understanding the root cause… and how I found those root causes.

Fix the Problem IX: Three High-Scrap Issues on a Product Family – Tracing the root causes and eliminating the scrap on three different automotive radiators.

Fix the Problem X: Learning from Interview Problems  – Three short case studies of problems I was presented with in interviews, as a part of seeing how I approach problems.

Fix the Problem XI: The Measles Chart – A very simple graphic, used as a first-pass data collection scheme in production trouble-shooting, can reveal tremendous amounts of useful information.

Lean Manufacturing: Weighing Theory vs. the POF – Lean Manufacturing in Theory and Practice, with a case-history overview.

Fix the Problem XII: When Chemicals Attack – Three short examples, with lessons-learned, about when chemicals attacked products and/or equipment.

Pegging Out the Nerd-O-Meter: My Morning Commute – A statistical analysis of my morning commute time.

 

CAD MODELING WRITE-UPS FOR STUDENTS AT UMASS/Lowell AND MOUNT WACHUSETT COMMUNITY COLLEGE (Solidworks)

Homework: A “Toe clamp”. 

Toe Clamp

Homework: A measuring cup. 

Measuring Cup

Homework: Lofts and Sweeps (and capturing Design Intent)

Mouse with cord

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