Expert Details

Expert in Low Temperature Cofired Ceramic, Microsystems manufacturing, Six Sigma, Lean & Process Engineering

Expert ID: 732003 New Mexico, USA

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An accomplished professional that has increased yields to well over 90% and reduced flow times by over 75%. Developed new processes and products that have generated new customers and millions in sales. These new processes and products have generated 3 patents and many patent applications.

These accomplishments have been achieved over many years of professional experience with increasing levels of responsibility including project leader and supervisor. Most of this time spent in manufacturing environment but have also been a Staff Member at two National Laboratories. Experience with and built components for Radars, Telemetries, Firesets, Satellites and Secure Electronics. Job functions have included Basic Research, Quality Control, Quality Assurance, Manufacturing and Project Management. Work environments range from running own company, working in private industry to working as a government contractor and as a government employee.

Quality Assurance and Quality Engineering skills including writing Quality Assurance Plans, review of quality records before submittal to customers, audits of production processes, audits of vendors, establishment of quality control points, writing inspection instructions, writing inspection travelers, verifying quality inspection methods, investigation and root cause analysis of production errors, review and approval of Corrective Action Reports as a Corrective Action Coordinator.

Manufacturing and Engineering skills including sustaining processes, enhancing yields, purchasing equipment, modifying equipment, specifying materials and developing new processes. Also have experience working with and building parts to drawings and designs, material and process specifications, vendor interface and quality audits, establishment of in-process verification to assure product quality, setting up production travelers, process instructions and bill of materials.

Project and Management skills include budgeting, planning and resource allocation for short term and multi-year projects ranging in value from tens of thousands to multi-millions of dollars. Assembled engineering teams to work on specific products and technologies which included directing the efforts of up to 16 people.

Statistical techniques and Six Sigma tools including Process Mapping, Measurement System Evaluation (MSE), Cause and Effect (C&E), Quality Functional Deployment (QFD), Failure Modes and Effects Analysis (FMEA), Design of Experiments (DOE), Statistical Process Control (SPC), Lean Methodology, Root Cause Analysis and Mistake Proofing.

Black Belt Projects have included evaluating, characterizing and optimizing new and old processes, materials, equipment and products. Participated in the publication of a Design for Manufacturability (DfM) guide.

Clearances: hold security learances from the Department of Energy and the Department of Defense


Expert may consult nationally and internationally, and is also local to the following cities: Albuquerque, New Mexico - Rio Rancho, New Mexico

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Education

Year Degree Subject Institution
Year: 1981 Degree: BS Subject: Ceramic Engineering Institution: Alfred University

Work History

Years Employer Title Department Responsibilities
Years: 2011 to Present Employer: Undisclosed Title: Chief Technology Officer Department: Responsibilities: Cofire Ceramic Associates provides training in six sigma black belt, six sigma green belt, designing for six sigma, lean manufacturing, root cause analysis, mistake proofing, process engineering, and project management. Also provides consulting services in low temperature cofire ceramics, high temperature cofire ceramics, microelectronic manufacturing, and microsystems manufacturing.
Years: 2010 to 2011 Employer: Air Force Nuclear Weapons Center Title: System Engineer Department: Test and Evaluation Group / Engineering Directorate Responsibilities: System Engineer in the Test and Evaluation Group in the Engineering Directorate. Group responsible for all systems including Gravity Bombs, Cruise Missiles and Re-entry Vehicles.
Years: 2009 to 2010 Employer: Sandia National Laboratory Title: Technical Team Leader Department: Export/Import Control Office Responsibilities: Team Leader of the Export/Import Control Office (EICO) supervising a staff of four Analysts that provided analysis, advice, training and support to the Laboratory staff on export/import issues involving the EAR and ITAR regulations.
This included processing a variety of Temporary and Permanent Export and Import licenses, agreements, exceptions and exemptions. Worked to determine customer needs, regulatory requirements, map processes and find improvement opportunities. Worked to reduce cycle times by 75% by setting up task tracking and improving customer interface by reducing and focusing required customer inputs.
Years: 2009 to 2010 Employer: Charles Stark Draper Laboratory, Inc. Title: Senior Quality Engineer Department: Production Quality and Analysis Department Responsibilities: Senior Member of Technical Staff working as a Senior Quality Engineer in the Production Quality and Analysis Department supporting the development, prototyping and manufacturing of the Inertial Measurement Unit and Guidance system for Trident Missiles. Worked on component qualification for an upgrade to the Trident Guidance, Navigation and Control system. Also responsible for electronic component receiving inspection. Worked to understand customer needs, quality requirements, map processes and find improvement opportunities. Used this information to initiate effort to reduce cycle time in by 75%.
Years: 2005 to 2008 Employer: Los Alamos National Laboratory Title: Quality Engineer Department: Quality Performance group Responsibilities: Technical Staff Member working as a Quality Engineer in the Quality Performance group that is part of the Stockpile Manufacturing Support division working with departments that deliver Telemetries, Detonators, Explosive Powders and Materials. Responsibilities included preparing parts and their quality packets for submission to the customer. Performing audits and evaluations of processes, and identifying concerns. Corrective Action Coordinator (CAC) for Corrective Action Reports (CARs) that identify manufacturing and documentation deficiencies. Developed and implemented Quality Assurance Plans. Key contributor to the Weapons Quality Assurance Plan now in use by Los Alamos National Laboratory Production Agency. Assisted organizations in setting up Production Process, Process Instructions, Inspection Points and verifying Inspection Methods accuracy and repeatability.
Years: 2004 to 2005 Employer: Cofire Ceramic Associates Title: Chief Technology Officer Department: Responsibilities: Company provided consulting services in low temperature cofire ceramics, high temperature cofire ceramics, microelectronic manufacturing, and microsystems manufacturing Also, provided training services in six sigma black belt, six sigma green belt, designing for six sigma, lean manufacturing, root cause analysis, mistake proofing, process engineering, and project management. Company includes eight engineers and scientists all with at least 20 years experience in their specialty.
Years: 1991 to 2004 Employer: Honeywell International Title: Microsystems Engineer / Project Leader Department: Microsystems Network Fabrication Responsibilities: Staff Engineer working as a Microsystems Engineer and Project Leader of effort to manufacture custom ceramic packages for microelectronics and microsystems. This effort based on Low Temperature Cofired Ceramic technology in an ISO 9001 facility. This included directing technical efforts, planning, budgeting, and consulting with customers on technology selection. Delivered hardware supporting MEMS Packaging, Telemetry (Wireless Communication), Programmers, Controllers, Secure Electronics, Radars, High Speed Electronics, High Voltage Insulators and Satellites.
- Achieved manufacturing line yields in the high 90% range.
- Fastest microelectronics technology development and implementation ever at this facility from the time the base technology was brought on-line to first substrate qualified and put into production.
- Specified, built, equipped and brought on-line new low temperature cofiring ceramic microelectronic fabrication facility.
- Specified, purchased, characterized, optimized and qualified for production use new low temperature cofiring ceramic microelectronic fabrication equipment.
Years: 1984 to 1991 Employer: Honeywell International Title: Microelectronic Assembly Engineer Department: Albuquerque Microelectronics Operation Responsibilities: Packaged silicon semiconductor devices to Mil-Std-883. Primary responsibility for Wafer Dicing, Die Separation and Sorting, Cleaning, X-Ray Inspection, Gross Leak, Fine Leak, Temperature Cycle, Stabilization Bake, Laser Marking, and Lead Forming. Experience with Eutectic and Epoxy Die Attach, Aluminum Wire Bonding, Belt Sealing, and Hot Platen Sealing. Consulted on package issues, and on Failure Analysis of devices and determination of contamination sources. Implemented an operator certification program.
- Production Line Yields increased from 75.6% to 93.9%,
- Sealing Yield increased from 83.4% to 98.1%;
- Flow Time reduced from 60.2 days to 23.1 days.
- Department won a Department of Energy Award for Quality Improvement.

Career Accomplishments

Associations / Societies
American Society for Quality, Senior Member, International Microelectronics and Packaging Society (IMAPS), American Ceramic Society, National Institute of Ceramic Engineers
Licenses / Certifications
Six Sigma Black Belt. Design for Six Sigma (DFSS) - All in the Honeywell Six Sigma Plus system. Lean for Six Sigma (LSS) from the University of Michigan through Los Alamos National Laboratory. Certified Quality Engineer (CQE) through the American Society for Quality
Awards / Recognition
Kansas City Plant Special Recognition Award for Development of Low Cost RF Package. Sandia National Laboratory Employee Recognition Award Nomination for team that built and demonstrated first fully functional MEMS Microsystem for future production application. Kansas City Plant Special Recognition Award for Development of Low Cost LTCC Cavity Formation Process. Department of Energy Defense Programs Award of Excellence for Manufacture of the LTCC networks used in the High Explosive Radio Telemetry (HERT). Certificate of Appreciation for Successful First Production Unit and Sustained Production. Kansas City Plant ES&H Award for Less Hazardous Thick Film Resistor Implementation. Kansas City Plant Certificate of Appreciation for Quality Enhancement Program. Department of Energy Quality Improvement Award to AMO IC Packaging
Publications and Patents Summary
Expert has 7 publications and 3 patents

Fields of Expertise

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