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PRODUCT DESIGN & MANUFACTURING ENGINEER / PROJECT MANAGER
Highly skilled and versatile senior product design engineer / project manager with 20+ years' experience in conceiving and
developing innovative, appealing designs and turning them into manufacturing reality and profitable products. Self-motivated,
methodical, detail oriented and energetic multitasker with passion for design. Works well both independently and as a team
member or managing cross-functional teams. Seeking to engage in new challenges and learning experiences, while delighting
customers, mentoring others, furthering professional growth and the growth of the organization.
Working for small companies has allowed full mastery of the design and manufacture process from product conception through
release in the marketplace, while active involvement in all phases has provided me with a broad and comprehensive skill set. My
experience combined with business acumen allows me to help solve strategic business problems and manage cross-functional
teams effectively.
EXPERTISE
- R&D
- 20+ years of project management / lead designer experience
- Product invention/design
- Making products that fulfill the required function and appeal to the potential customer at correct price point
- Realizing product opportunities (improving existing products or creating product innovations)
- Product creation using hand sketches and SolidWorks CAD/CAE
- Brainstorming conceptual ideas to iterate to better product solution
- Hands-on prototype creation and internal/external testing in models and cadavers
- Performing prototype iterations with necessary course correction activities based on results
- Design control
- Optimize design for manufacture using DFM, DFA and DFS principles and best practices
- New Product Introductions (NPI)/transferring prototype designs smoothly from R&D to manufacturing
- Managing cross-functional product design/manufacturing teams
PROFESSIONAL EXPERIENCE
PRIMO MEDICAL GROUP — West Bridgewater, MA 2022 - CURRENT
Senior Design Engineer
Part of a cross-functional team responsible for transferring a new robotic platform from a prototype to production. Designed
and manufactured a wide range of fixturing to help aid in the assembly of the robotic platform and the consumable surgical
instrumentation. In charge of ensuring robot parts and assemblies were optimized for DFM and DFA whilst maintaining high
quality.
Highlights:
- Working on a new surgical robotic platform.
ACTIV SURGICAL —Boston, MA 2021 - NOV 2022
Manager, Advanced Manufacturing Group
Champion the design of products which perform well and enhance the user experience. Optimize prototype designs for performance,
manufacturability and serviceability in parallel. This approach reduces development time and ensures the original design intent is not
diminished as a result of redesign for manufacturability. Accountable for the practical application of product design for excellence
principles. Evaluation of post market surveillance data for ongoing continuous improvement of commercially released product.
Highlights:
- Received Marketing Director recognition for a sleek, innovative product packaging design that
reflected the high tech look and feel of the Activ Surgical product line.
- Designed workstations with equipment, fixtures and hand tools.
CONCERT MEDICAL (Theragenics Inc - Medical device design engineering) — Norwell MA
2020 - 2021
Senior Design Engineer
Designed and manufactured a wide range of equipment to produce Cardiology and Neurological guidewires. In charge of
ensuring new products and equipment were optimized for ergonomics and performance. In addition, assured these guidewires
were optimized for DFM and DFA whilst maintaining high quality. Supported all phases of existing product life cycles,
performing product design improvements and cost reductions.
Highlights:
- Rehired to perform upgrades to highly successful Profile Grinder equipment I had designed and manufactured over 20 years previous.
MEDROBOTICS INC — Raynham, MA
2017 - 2020
Senior Product Design and Manufacturing Engineer / Project Manager
Design surgical instruments and support equipment for robotic surgery. Transition surgical solutions from R&D to production.
Ensure DFM, DFA and DFS whilst maintaining a high quality, reliable and low-cost manufactured product. In addition, support all
phases of existing product life cycles, performing design improvements and cost reductions.
Highlights:
- Lead product designer managing one mechanical designer/drafter on pioneering robotic surgical instrument support to allow deeper colorectal surgical procedures and use of a wider range of instruments and products.
- Lead product designer / project manager overseeing three people on redesign of robotic arm. New arm performed better, was easier to manufacture and cost 20% less to produce.
- Perform Design Failure Mode Effects Analysis (DFMEA) and Process Failure Mode Effects Analysis (PFMEA) to allow robotic arm changes to be transferred into production.
- Provide direction and mentorship for interns, peers and colleagues
CONCERT MEDICAL LLC (
formerly Accellent Inc., medical device design & manufacture) — Norwell, MA
2005 - 2017
Senior Product Design & Manufacturing Engineer
New product concept development and transition from R&D to production. Performed design revisions and cost reduction through
better manufacturing and outsourcing to add quality and value. Supported all phases of product life cycle.
Highlights:
- Career highlight — Co-inventor of patented design for lap joint for wire hybrid stainless steel and nitinol guidewire (Patent US 20070282270 A1).
- Career highlight — Co-inventor of patented design for lap joint for wire hybrid stainless steel and nitinol guidewire (Patent US 20070282270 A1). This challenging metal joint allowed the company to sell its own hybrid wire without having to pay royalties for the use of a competitor's patented joint design.
Accellent Inc (
formerly Microspring Inc., Medical device design & manufacture) — Norwell, MA 1999 - 2005
Senior Lead Design & Manufacturing Engineer
Served as project manager / lead for cross-functional team of technicians, machinists, electronics engineers and draftsmen. Managed resource allocations, budgets, and milestone adherence.
Highlights:
- Co-designed and developed Urology Stone Cone lithotripsy prototype device with transfer of prototype device from R&D to production.
- Career highlight - Co-designed and manufactured a specialized corewire to allow a built-in blood pressure sensor to be embedded in it. Helped transition this prototype design into production.
- Career highlight - Designed lean manufacturing fast change over tooling for grinders, reducing setup times by 60%.
Microspring Inc (
Medical device design & manufacture) — Norwell, MA 1996 - 1999
Lead Design Engineer
Highlights:
- Career highlight - Project Manager/Lead Design Engineer of cross-functional team in charge of $1,000,000 budget to design and manufacture 7 State of the Art Precision Guide Wire Grinding Machines to grind precision shapes in 0.014" Dia stainless steel and Nickel titanium wire to 0.001" +/- 0.0001". Project completed on time and on budget and still in operation today.
- Career highlight - Project manager in charge of setting up infra structure for new grinding facility
which included the seven new state of the art grinders and all necessary support equipment.
- Designed and implemented a variety of high speed 0.014" Dia stainless steel coil winding equipment with automated feeding and unloading systems.
Glebar — Franklin Lakes, NJ 1988 - 1996
Research & Development Engineer
Highlights:
- Performed R&D to conceive or improve grinding machine tooling and equipment to achieve low cost manufacturing.
EDUCATION & CREDENTIALS
Loughborough University - Leicestershire, England, UK
BSc (Hons) Design and Manufacture Engineering, 1988
Diploma in Industrial Studies, 1986
Mass Art - Boston, MA
Industrial Design Continuing Education Class Credits, 2017
American Management Association, Certificate in Business Management (1996)
