•Design tooling for the die cast process
•Research and recommend manufacturing technology (Vacuum, squeeze, software, automation)
•Lead cross functional teams to interact with major customer teams (Bosch Rexroth, Gilbarco, Genie, Cummins, Whirlpool, Motorola)
•Significant cost reductions and product improvement for the Kitchen Aid Stand mixer castings.
•Worked with Rexroth Corporation and designed the fuel pump body casting that is used on the Ford PowerStroke diesel engine. I managed the tooling for this program that included 24 die casting dies during the life (10 years) of the program.
•Worked with take over tooling to solve problems (usually the tooling produced unacceptable levels of porosity and/or wouldn’t maintain a production cycle due to the design of the tooling) and produce quality castings. In all cases the tooling was revamped (gating, venting, slide design) so that the customer received satisfactory product off the tooling.
•Improved profits and increased productivity on existing dies through cycle time reduction, casting weight reduction, process evaluation, and gating review.
•Part design review for die casting including recommendations for draft, parting line placement (to enhance die life and facilitate trimming), ejector pin locations, gating, overflow and venting analysis on tooling designs.
•Process parameters and die cast machine sizing recommendations for new and existing tooling. Recommendations for fill times and cavity pressure to improve casting finishes and reduce shrinkage porosity.
•Developed die maintenance system to extend the life of tooling
•Lead process control development for improvements to the die cast process.
