NER Application Work Experience And Acquired Competency Statement

I have used my three “Career Episode Descriptions” to detail out the 3 critical projects that I have worked in the past 12 years for various employers.  

EMPLOYMENT HISTORY

PRODUCTION ENGINEER, NEW PRODUCTS

Started Full time employment as of FEB 2018 – Currently employed

Employer name: PC LOCS https://www.pclocs.com.au/

Location/address: 29 Oxleigh Dr, Malaga WA 6090

MAIN RESPONSIBILITIES:

• Ensured that the new product design being introduced is manufacturable in a repeatable process flow.
• Designed Supply Chain, Assembly & test process flow for the new Products.
• Performed DFX (DFM- Design for Manufacturing, DFT- Design for Test) for new products being introduced
• Ensured that the personnel are trained and certified to produce the new product
• Ensured that the infrastructure (factory and Supply Chain) for the new product is adequate and well defined
• Ensured that the methods used to produce the new product are fully defined and validate
• Ensured that the metrics used to assess the new product specifications are defined and practical.
• Ensured the Pilot is properly managed to prove out the design, the process and the supply chain before the final release to production
• Responsible for Product stability of all released and active product
• Utilized and identified trends using the KPI’s or Roll Throughput data internally and with the Suppliers and CM’s.
• Generated, reviewed and approved for all product related changes
• Provided design analysis, component selection, qualification test plans and implementation strategies for obsolete (EOL) component and Modules contained in released products
• Worked closely with Production Process Support when engineering evaluation is needed. Prepare engineering report of evaluation.
• Conducted MRB Review and disposition of all discrepant materials.
• Provided general support and continuity of production throughout the Operations
• Lead or be part of project(s) that will create and/or enhance processes, systems that improve: Productivity, Data and trend analysis and Cost reduction
• Lead NPI (new product Introduction) Life Cycle (Breadboard-> Prototype->Pilot-> Manufacturing Release- Sustaining Engineering) within the team.
• Uphold the company’s core values of Integrity, Innovation, Accountability, and Teamwork.

SENIOR MANUFACTURING PROCESS ENGINEER (NEW PRODUCTS & SUSTAINING ENGINEERING)                                           January 2015 – January 2018

Employer name: SCIEX INC https://sciex.com

Location/address: Blk 33, Marsiling Industrial Estate road 3, Singapore 

Main Responsibilities:

• Designed and developed manufacturing processes, Design for Manufacturability, BOM Product Structure during early VAVE opportunity generation and New Product Development and assess the potential risks and benefits to manufacturing.
• Provided manufacturing feasibility analysis for new ideas and VAVE opportunities
• Used preferred or re-use of components/design across Value Streams where technologically viable in VAVE and New Product Development projects
• Responsible for the timely introduction of Value Engineering and New Product Development projects into manufacturing through functional and assembly evaluation verification
• Worked closely with Production Process Support when engineering evaluation is needed. Prepare engineering report of evaluation
• Responsible to work with Production Process Support Engineering to generate potential VAVE project funnel opportunities
• Developed assembly and commissioned procedures for new Value Engineering and New Product
• Reviewed the outsourcing approach for defined assemblies, determine impact to internal manufacturing operations, update documentation with PPS where required
• Provided training as needed for new manufacturing procedures when a VAVE or New Product Development project is phased in to manufacturing
• Provided training, coaching and certifying fellow engineers on the ECO process
• Provided hands-on technical support to project teams in terms of instrument build and troubleshooting
• Provided Mechanical Sustaining Engineering support
• Specified the user requirements, for instance equipment manuals for the operators, of new equipment used within Production or within R&
• Ensured Adequate Supplier Selection
• Lead in Acceptance testing and installation qualification of equipment
• Transferred of equipment and process to manufacturing
• Lead improvements on installed production systems

NER Work Experience Statement:- Career Episode -1

Project- 1 Description:  

My first project deals with the assembly of universal nanocell. I worked on this project for a duration of one year, from April 2016 till April 2017 with SCIEX INC (Life Science Company under Danaher Group) in Singapore. My role in this project was that of a senior manufacturing engineer where I was given the task of handling new products along with their sustaining. 

During this project, my key responsibilities as a Senior Manufacturing Process Engineer included:

• Set up and debugged the commissioning issues in Assembly fixture and Test Fixtures.
• Ensured that the compliance Engineering (CE), UL/CSA regulatory standards, ISO 9001 and DFM standards were followed during new product transfer to the factory.
• Analysed the production throughput and detected the factory resource issues
• Analysed and detected the Process Failure Mode by performing Process Failure Mode Analysis (PFMEA)
• Implemented the corrective actions to mitigate the process related risks
• Created and issued instrument crating and product packaging procedure that would help shipping department for safe product transport.
• Drafted and issued the “Assembly Method Procedures and Test Method Procedures”.
• Lead presentations and chair meetings between the production team, material procurement, critical R&D members and shipping team for making sure that all the nonconformity was properly addressed.
• Prepared Bill of Material (BOM) and product structure for the improvement of new and existing products by using ENOVIA and SAP software.
• Published the shipment schedules of the new product for first six months.
• Prepared the process flow charts for the “Production process visual aids” using Microsoft Visio software.
• Arranged Bi-Weekly meetings with installation team, production management, shipping team and R&D team to analyse any site installation issues.
• Performed the Mock Line Audits to ensure that the production line was free from discrepancy.
• Reviewed the work cell layout of the Nano cell assembly.
• Determined the number of technicians required for the assembly and product testing.

Personal Engineering Activity

• Design of Test Fixture

This project involved the processes of process designing and manufacturing. My first task in the project was designing multiple assemblies and test fixtures. I designed the capacitor to ring lug soldering fixture which had two parts in its design. The first part of the fixture design involved the process of cutting and bending the capacitor leg into the exac length and shape which was required. The second part of the design consisted of locating the capacitor for the proper soldering process.

• Package Designing of Nanocell Assembly

To carry out the task of package design for the nanocell assembly, I created and issued the instrument crating and product packaging procedure in order to ensure secure transport of the product by the shipping department. I was also involved in the task of designing the packaging of the nanocell assembly in order for safe shipping of the product. I designed two foam layers in which the nanocell assembly was sandwiched. The foam layers were placed on the top and bottom of the nanocell assembly. I placed the packaged foam into a cardboard rectangular shaped box.

I proposed the press over the support fixture in order to push the heat sinks together as it was very important to ensure that the heat gets properly entrapped between the heat sinks for an efficient heat transfer.

• Press Fit Process using Alignment tools

I introduced the usage of alignment tools for the correct placement of heat sinks to ensure proper heat transfer. With the help of alignment tools, I aligned the bottom and middle heat sinks. This provided adequate heat transfer across the unitsfor the manufacturing process. I also used the alignment tools for the press fit process in which the contact terminal was pressed on the printed circuit board.

• Testing the Heat Transfer

The heat transfer of the product needed to be checked consistently due to which I commissioned the test fixture to detect the temperature of the product chamber wall surface through a thermography camera. I collected all the recorded temperature values in software which compared the recorded temperature values with the ideal values over a fixed period of time. This comparison kept a check of the consistency of the heat transfer process across the product.

• Statistical Quality Control

In order to understand the variations in the manufacturing process and the functionality of the instrument over a defined period of time, I conducted and performed the statistical quality control chart calculations. The quality control also ensured that the heat transfer within the product was within the required limits. I also performed time studies on the assembly to note down the assembly time and test time during heat transfer.

• Interfacing the nanocell assembly

For interfacing the nanocell assembly, I applied the computer integrated manufacturing along with the different principles of thermodynamics and mechanical engineering to test the requirements of heat transfer, press fit process, and supply chain design.

                               Figure 3-CE-3 Capacitor to Ring Lug Soldering Fixture

                                  Figure 6 -CE-3 Press Fit Process showing the use of Alignment tools

I followed the ASME, ASTM and IPC standards to ensure that all the related engineering drawings, system interconnect drawings, mechanical assembly procedures, material testing and capacitor soldering process met the proper standards and requirements of safety and performance. I utilized the SAP MM Module, Solid works, Oracle, MS Word, MS power point, MS Access, MS Project Management, MS Visio, MS Excel, HP version- FMEA Software, Minitab- Statistical Software and the HP version-process Mapping software in order to complete the different tasks of the project.

Apart from designing the nanocell assembly, I drafted and issued the assembly method and test method procedures. I also lead presentations and chair meetings between the production team, material procurement, critical R&D members and the shipping team in order to ensure that all technical procedures, as well as issues, were fully addressed. I prepard the Bill of Material and product structure using ENOVIA and SAP software for the improvement of existing products. I used the Microsoft Visio software to develop flowcharts for the visual aids of the production process.

Technical Problems 

I faced a technical problem during the preparation of the capacitor soldering methodology. I soldered the capacitor legs into the ring lugs and then removed the water-soluble flux in order to clean the assembly. Due to the presence of the water-soluble flux, the problem of minimal degassing occurred which needed to be taken care of immediately or else it would have affected the performance of the nanocell assembly. In order to remove the water-soluble flux, I used the capacitor soldering tool to bend the capacitor leg into the desired shape and cut off any extra material. I also used the soldering tool to locate the capacitor with ring lugs. After completing the process of soldering, I used a deionized water bath and heated it up to a temperature of 50 to 60°C. Next, I dipped the soldered capacitor assembly into the heated water bath for about three to five minutes. The heated deionized water removed the water-soluble flux. This whole process of removing the water-soluble flux took about 20 minutes.

Another issue that I faced during this project was the process quality control of spot welding of the capacitor assembly as well as the heater tab to the nanocell base part. I proposed a solution to the problem by visual inspecting the spot welding process with a microscope. I developed an outgoing inspection report based on the visual inspection results which showed that the yield had increased up to 100%.

                        Figure 8-CE-3 Capacitor to Ring Lug Soldering Process and Cleaning

Another issue that I faced during this project was the process quality control of spot welding of the capacitor assembly as well as the heater tab to the nanocell base part. I proposed a solution to the problem by visual inspecting the spot welding process with a microscope. I developed an outgoing inspection report based on the visual inspection results which showed that the yield had increased up to 100%.

Compliance with Quality:

I ensured that the compliance Engineering 9CE), UL/CSA regulatory standards, ISO 9001 and DFM standards were followed when dealing with technical issues. I analyzed the production throughout the whole process in order to detect any factory resource issues. I performed the process failure mode analysis PFMEA to analyze and detect any process failure mode. I also performed the mock line audits to ensure that the production line was free from any technical problems.

During the commissioning of the mass specification instruments, I conducted an instrument level test conduction. I installed the universal nanocell assemblies to the instrument in order to ensure the safe usage of the product. I performed the EHS audits so that the source changing does not affect the instrument vacuum system.

Team Management and Project Management:

I motivated my team to achieve the highest possible performance while maintaining a friendly environment in the workplace. I believe that the act of empowering others results in extraordinary achievements and I repeatedly practiced this idea during my career. I made small teams which consisted of four to five members to work on a certain task and appointed their leaders. I directly communicated with the leaders of these groups about their performance. This distribution of tasks made sure that tasks were completed in a timely and productive manner without using excess resources of the organization.

I believe that an in-depth understanding should be developed before starting a project of a complex nature. A project consisting of a great number of stakeholders, variables, and features cannot be carried out by a single man. Therefore, teamwork becomes a necessity in the present day’s industrialized world. I was delivering my duties in the capacity of a team leader and also faced some challenges. I overcame these challenges by employing the principles of motivation, delegation, communication, development, transparency, and discipline.

I am fully conscious of the fact that a high-performing team is composed of individuals who share a common vision in terms of business and organization. I conducted training sessions where I instructed my team members to prioritize organizational and team’s objectives over their personal objectives. I motivated my team members even when they made mistakes. I repeatedly developed coordination among various teams within the organization. I worked and coordinated with functional, technical, development, and testing teams. I also directed technical teams so that they had a clear approach towards the project.

I faced some conflicts that arose because of the personal interests of my team members. In such cases, I strictly told these members to rescind their claims in favour of the organization. While maintaining a friendly environment in the workplace, I also made sure that discipline was not compromised and my team was working efficiently. Being responsible for my team’s performance, I motivated my team members to push their boundaries and reach their maximum potential. The extraordinary performance of a team depends upon the impressive performance of each individual, and I utilized this principle throughout my career. I made sure that all the members were well compensated for their work and motivated at all times.

I organized meetings with the project management and personnel to inculcate the present situation of the project among the project members. We discussed project improvement techniques, problem-solving ideas, and future tasks to be implemented in those discussions. I developed cordial relations with the project members to ensure harmony and work effectively within the company. I tackled each problem with a technical mindset and a wise approach. I ensured the safety of the product and workers by implementing the company’s safety policies and professional codes of protection from work hazards. I monitored the progress of my group members and ensured that there was no violation of safety regulations.

During my all projects that I worked on during my professional career, I showed my high communication skills through participating in official meetings and by producing documents that included calculations, designs, and progress reports.

For the resolution of any issues encountered, I called of team meetings and discussed the possible solutions after the detailed analysis of the issue. I presented my opinion and also prioritize the suggestions of the other team member. I prepared a report on it and forwarded it to management to take their consent.

Ethical Standards

As a senior employee, I adhere to the ethical and legal obligations of my position in order to meet the expectations of all stakeholders. I try to maintain a good moral behavior between every single employee. In case of any unethical incident, I try to remain calm and professional in order to resolve the issue. Being a senior employee, I give respect to new and junior employees, and by following the ethical standards, I try to set an example for them. When it comes to discussing the work I collaborate positively with clients and colleagues. I appreciate the positive work of my co-workers and speak up against negativity.

I have always been very cautious about my behaviour in professional career from the start and followed the basic ethical standards of professional life. I implemented the moral training and experience in my work which I gained through my studies and different experiences. Throughout my job history, I performed my duties passionately and followed the moral standards of the organization. I kept myself motivated to be punctual about my work by strictly following the work schedule, completing each task on time.

Risk Management:

I was responsible for identifying risks and developing a risk management plan before the execution of a project. Working on a broad spectrum of projects, I have developed several change management plans of varying ranges. My responsibility was to ensure glitch-free execution of planning, to organize, controlling, and influencing procedures. I forecasted the possible cost of the project and developed plans to minimize this cost without compromising quality.

Safety:

I followed a safety standard based on safety regulations and codes. But some of the instruction required more details. I made a change in work permits and added a row in the checklist. Throughout the project tenure, I followed the ASME and ISO standards to perform the calculations and also obeyed the OSHA standards to ensure safety from work hazards. I adopted safety procedures to design this project. I made sure that the first aid kit was available always on the working site. Moreover, I also instructed my teammates to follow safety standards to avoid mishaps. I guided them through every phase of the project and monitored their performance. I provided them with a friendly working environment. I used the personal protective equipment and also instructed the team to use it during work strictly.

Summary

I utilized my previous knowledge and experience of process designing and manufacturing process standards and achieved the 90% production test yield. I also trained the technicians to run the pilot production successfully. I introduced the Nanocell pre-spot weld continuity check, post weld continuity checks and 5S methodology for all the Production and test cells. I also gave the presentation to production on working principles of Nanocell assemblies and functional tester. I followed the manufacturing plan, sourcing plan and meeting minutes report to arrange meetings. Te plan report carried all information about the Nanocell assembly manufacturing process and test process.