Senior Manufacturing Engineer

John Douglass White B.S.E.

**** ** ***** ******

Shoreline, WA 98177

Ph: 425-***-**** / xy2gbh@r.postjobfree.com

Senior Manufacturing Operations Engineer with extensive experience in manufacturing, production and projects. An expert in efficiency with a drive for hands-on approach to products, processes and procedures. Solutions oriented utilizing timely methods and achieving quality end results.

Six Sigma Black Belt – ETI Group Cadence Project Management

Demand Flow Technology – JCIT OSHA Trained

IPC Specialist Certified ISO Trained

Electro-Static Discharge Trained SAP Trained

Professional Experience:

INTERMEC TECHNOLOGIES CORPORATION, Everett, WA & Cedar Rapids, IA 1998-2009

New Product Introduction (NPI) Engineer (2009)

Gathered prototype requirements/specifications with Design Team (Project Manager, Configuration Management, Software, S/W Test, Mechanical, Electrical, and Product Test Engineering). Assisted in the design, then developed and built prototypes, got drawing approvals, created BOMs and ECNs (Engineering Change Notice), designed production line, Operational Method Sheets, and test fixture setup.

• Created new BOM, build and cost structure for the 730 Brazil Project, allowing simple and easy assembly resulted in 80% cost savings for all units sold in Brazil.

• Prototyped CN3 Handheld computer for US Government contract to Navy (custom software and mechanical modularity allowed multiple data collection points with WAN radios usable worldwide). 5-year AIT-IV contract just approved.

• Developed and piloted custom PM Printer for Chinese Government.

• Ran successful pilot production of CN3 model to be sold exclusively in China.

• Developed and produced next generation SR61T Extended Range Tethered Scanner.

• Rolled out radio frequency option for barcode printers. Created BOM structure for production, field kits and service assemblies for all countries. Developed and implemented a modular design production structure which maximized scalability and ease of integration, increasing efficiency and eliminating production error.

Sr. Manufacturing Engineer (2003-2008)

Responsible for the highest production model sold by Intermec (700 Handheld PC) with over 1 million units sold worldwide, as well as the latest generation designs (CK61 and CN3 handheld PC’s). Designed and setup manufacturing lines, including tooling and capital equipment.

Implemented Demand Flow Technology (DFT), lean manufacturing principle and philosophy into the line design. Setup and verification of both ergonomic factors and ESD for work stations. Key liaison between management, departments and production teams to facilitate communication, training, needs and teamwork.

• Managed the new Layout of the entire production facility using Lean Manufacturing (DFT) design concept and floor arrangement. Worked with supervisors and engineers to accommodate specific individual product requirements while staying within design plan. Able to free up 25% of production floor space.

• Transitioned Media Production from Las Vegas, NV to Everett, WA. Led a team of four that maintained production volume while reducing presses and personnel by 75%. Total operational cost savings of $10 million per year.

• CN3 Handheld PC – Increased capacity and output by 50% (up to 600 units/day) without adding new production lines. Reverse engineered the CDMA radio assembly design to allow disassembly, rework, or repair of the radios to eliminating $80K in scrap.

• Designed Flexible Manufacturing mobile carts that would allow greater material space, cleaner lines, and ability to efficiently change lines for the manufacture of multiple products. Used across 2/3 of production floor.

• Build custom tooling and fixtures using fabrication shop equipment (i.e. drill press, table saw, band saw, belt sander and press). Managed project to build custom fixtures through fab shop or contract shop (milling machine, lathe and CNC).

• CRISP (Customer Request for Intermec Special Project): Piloted and released to production custom products for major customers with large rollouts.

* Created the ISO/9001 documentation for process flow and procedures.

* FedEx project required custom OS for Intermec’s top selling handheld device (700). Managed the pilot project; schedule, build, load, test, customer review/approval and release to standard production, including subsequent versions.

* Rolled out custom CN3 Royal Mail configuration, resulting in 20K unit sale in the first year alone.

Manufacturing Engineer (1998-2003)

Technical support for the manufacturing of multiple key products in the company. Troubleshot components or assemblies displaying form, fit or function issues; analyzed assembly and critical dimensions (through calipers, gages, micrometers, CMM, etc.) to determine root cause. Assessed the impact that current issue has on quality, as well as evaluated the bearing redesign will have on production. Partnered closely with Quality Engineering to quickly resolve vendor issues, including redesign.

• Manufacturing facility consolidation from Cedar Rapids, IA to Everett, WA. Overall cost savings to company of $28 million per year.

• 700 Handheld PC – Restructured the entire line design using DFT (lean principles) to allow better process flow while increasing production capacity, resulting in a jump from one line at 140 units/day to four lines at 800 units/day total.

• Media Duplication – Integrated multiple duplication systems into one. Expanded in-house capacity and flexibility for CD/DVD duplication through build-to-order system. Reduced inventory, unit cost ($200K/yr cost savings) and 100% elimination of scrap.

• Printers – Outsourced two major assemblies for Barcode Printers (eliminated 6 minutes off production build time, 10% reduction). Outsourced two assemblies for Dot Matrix Printers (eliminating 9 minutes off build time, 25% reduction). Key savings in resource allocation and throughput.

THE ERTL COMPANY (RACING CHAMPIONS), Dyersville, IA 1995-1998

Manufacturing/Process Engineer at a die-cast collectibles and toy production company. Programming and set-up of laser engraving equipment. Optimized processes for die-cast, machining, sub and final assembly production.

ROCKWELL INTERNATIONAL, Cedar Rapids & Coralville, IA 1993

Intern/ Research Assistant in concurrent engineering research project on risk analysis of circuit boards for military radios and black boxes.

CHUEN CHOW HIGH SCHOOL, Lungtan, Taiwan R.O.C. 1991

Teacher in English as a second language to various classes of high school students.

Education:

The University of Iowa, Iowa City, IA

B.S.E., Industrial Engineering – August, 1995

Specialization in Quality Engineering

Programming of CNC milling machines and lathes.

Computer Skills:

Languages: Basic, Pascal

Software Platforms: ProModel-PC, AutoCAD, SAP, Workmanager, Project Manager, JMP.

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