Manufacturing Engineer in Boston MA Resume Theodore Hotz by TheodoreHotz


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									                                          THEODORE HOTZ
                                                  Norwood, MA 02062

                                     MANUFACTURING ENGINEER
Results-oriented Mechanical Engineering Professional with broad background in the manufacture and test of electro-
mechanical products for the DOD secure communication systems industry, in an ISO-9001 environment. Skilled
supporter of all business units, including Engineering Product Development, New Product Qualification, Shop Floor,
Incoming Inspection, Quality Control, Engineering Test, and Procurement. An organized and effective problem solver
with proven record of achieving both immediate and long term needs of the business, ensuring project success and on-
time delivery. Focused, technically savvy, a quick study in emerging technologies. A trainer and mentor. Recognized by
management as an excellent resource and a welcome addition to any team.

                                             CORE COMPETENCIES
Large and Small Systems • Manufacturing Process Development & Improvement • Fiber Optics Assembly & Test
  Tool & Fixture Design • Root Cause Failure Analysis • Microsection Analysis • Materials Test & Evaluation
        Radiographic Analysis • PWB Internal Structure Analysis • Test Plan Development & Execution
      Environmental Testing • SolidWorks 3D in Training • Microsoft Office Suite • Communication Skills
                                         Current SECRET DOD Clearance

                                         PROFESSIONAL EXPERIENCE

General Dynamics, Needham and Taunton, Ma.
1974– 2011
Senior Manufacturing Engineer
Performed component characteristics testing, field failure root-cause failure analysis, and supported new product
Engineering Qualification System Test. Resolved in-house and outside contractor quality, reliability, performance, and
process issues associated with metalworking & finishing processes, electro-mechanical sub-assemblies, and PWA
component and solder issues across all Programs. Supported four Work Centers, working to improve product quality and
reliability, to improve yield, and to introduce more efficient processes and technologies. Identified need for new capital
equipment or manufacturing processes, presented business case to Management, and initiated approved purchases.

        Identified a weld design flaw that caused winch mounting bracket failures on hundreds of fielded military mobile
        antenna masts. High Visibility Project because of the potential risk for catastrophic mechanical failure and
        serious physical injury to field personnel. Redesigned the anchor pin weld on the bracket and performed design
        validation tensile tests. Mast OEM adopted the design change and upgraded all fielded masts with new brackets.
        Established a 1,000 sqft Work Center for the assembly and test of Fiber Optic components for a new multi-million
        dollar Mobile Field Communications System for the Army. Purchased all capital equipment, developed and
        documented all assembly and test procedures, designed all fixtures & tooling, and trained all work center and
        Quality Inspection personnel. Received a Superior Performance Award for completing this project on time and
        on budget.
        Developed specifications for and supervised fabrication of a $250,000 Automated Test Equipment hardware
        upgrade. Upgrade was needed to meet production schedule for pin-to-pin continuity and shorts testing of a 3,000
        point, wired backplane for a new Army project. The upgrade exceeded expectations, reducing total test set-up
        time by 25 minutes per unit.
        Established an automated component lead tinning work cell utilizing a six axis robot and a bench top wave solder
        machine. The automated system eliminated the need for hand tinning of critical parts.
        Upgraded semi-automatic ribbon cable terminating machines with vision systems. Upgrade eliminated part miss-
        registration errors and reduced waste by 74%.

             Bachelor of Science, Mechanical Engineering Northeastern University Boston, MA

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