![Technical Dimensions LLC Greg Sample, Sr. Consultant 3601 Madrona Drive Newberg, Oregon 97132-1557 T: 503-538-9244 F: 503-538-9244 M: 503-200-8245 (Domestic U.S.) M: 86-134-3402-0075 (China) [email_address] [email_address] Mechanical & Manufacturing Development Consultant](https://image.slidesharecdn.com/technical-dimensions-llc-1230565719328116-2/85/Technical-Dimensions-LLC-1-320.jpg)
Technical Dimensions LLC
- 1. Technical Dimensions LLC Greg Sample, Sr. Consultant 3601 Madrona Drive Newberg, Oregon 97132-1557 T: 503-538-9244 F: 503-538-9244 M: 503-200-8245 (Domestic U.S.) M: 86-134-3402-0075 (China) [email_address] [email_address] Mechanical & Manufacturing Development Consultant
- 2. Experience / Capabilities 28 years in mechanical design; components, products, process & tool development 24 consecutive years of Asian business experience in 8 countries Mid-level ability to communicate in Mandarin Chinese Hands-on experience in part and product design, specialist in manufacturing processes, tooling and material selection Demonstrated success directing mechanical design teams, product development teams, quality assurance departments, suppliers, transition of products into manufacturing, tooling development and, tool and process transfers to new suppliers National and International design awards in die-casting, injection molding and Thixomolding Numerous personal and team patents for component and process designs Proven ability to innovate, reduce costs, improve quality and reduce schedule
- 3. Consulting Services Concept Brainstorming Risk / Cost / Quality Assessment of designs and concepts Component Design Assistance: (Design for Manufacturability, Design for Assembly) Cost and quality optimization of new and existing parts Material and process selection Concurrent development with client design teams to eliminate serial feedback from supplier and impacts to schedule and cost Manufacturing process development Assessment / analysis of existing parts Redesign of existing parts / Alternate design concepts Research new materials and processes Specification reviews, recommendations Schedule Development: Component Design & Cost, Tool and Process, Project Supplier Evaluations / Risk Assessment / Recommendations / Management / On-site visits Manufacturing Tooling: Provide direction to suppliers or procurement teams during the RFQ process Tool design review to assure quality, life and cost targets are met Filling analysis to assure quality and schedule are met Management of suppliers during tool and process development Evaluation of tool tests, recommendations for tool corrections and design changes FAI / CpK development and evaluation New part analysis (form / fit / function)
- 4. Recent Projects / Contributions Saw Stop, Tualatin, Oregon: Engaged by Saw Stop to cost-reduce the primary components in their “Saw-Stop” safety module and saw-blade Arbor used in wood processing equipment. Evaluated costs, manufacturing locations, materials, processes and designs of existing plastic and metal parts to uncover areas for possible reduction. Provided a 3-level analysis with part design details, CAD models, supplier recommendations and new costs to Saw Stop: 1.) Current part designs produced at new manufacturing suppliers. 2.) Subtle design changes to current parts with manufacturing at new suppliers. 3.) Complete re-designs with new materials, processes and suppliers. Result: Saw Stop is currently implementing combinations of levels # 1 & # 2 which will yield an overall cost savings of 36% for the safety module. The remaining parts in the module will undergo similar changes after the primary parts and will yield an additional 20% savings. The saw-blade Arbor cost proposal resulted in a 64% reduction that is also being implemented. Managed new suppliers during tool, process and sample part development in China. Monitored technical communication for Saw Stop after the transition to new suppliers.
- 5. Recent Projects / Contributions Ostendo Technologies, Carlsbad, California Acquired by Ostendo as an extension of their mechanical design team for concurrent development of a large, leading-edge curved monitor for the gaming market. The goals were in keeping costs and schedule to a minimum while maintaining design intent. Daily dialog with the Carlsbad design team and remote industrial designer to review and update design files, direct part designs for manufacturability, assembly, tooling and process best practices and, material selections. Provided alternate part designs, features, material and process selections and specifications. Parallel to directing part designs within each category, suppliers were recommended for die-casting, plastic injection molding, compression molding, extrusion, thixomolding, as well as large and small stamped parts. On-site assessments were completed in Asia for all new sources prior to recommendations being finalized. Collaborated directly with all suppliers as a technical liaison to initiate the relationship, direct the RFQ process, kick-off tooling, request sample parts and optimize manufacturing processes. Completed tool design reviews, fill analysis and final tool design-approval. Evaluated sample parts and inspection reports on-site at suppliers. Recommended solutions to problems found. Result: Product cost targets, component quality and tool development schedules were met or exceeded. In most cases, Ostendo did not have manufacturing sources for these components or an internal ability to fully design for tool and process needs. Created additional time for part designers to complete other design and validation tasks (critical to a young and lean-staffed start-up)
- 6. Recent Projects / Contributions Light Speed Aviation, Lake Oswego, Oregon Engaged By Light Speed Aviation in several capacities: brain-storming of new product concepts, cost reduction / quality improvement of existing products and, development of new high-end audio products used in the aviation industry. Evaluated field-returns of existing components to assess failure symptoms, determine root-cause and to define solutions. Solutions were implemented and measured to assure root-cause had been addressed. Conducted on-site assessments of Chinese manufacturing sources to assess capabilities and capacities as well as to gather details toward resolution of problem areas. Provided real-time design feedback and direction during development of a new model earphone and battery module to assure cost, quality and schedule were met. This included plastic material and process recommendations, definition of secondary processes, alternate part designs, design direction of internal designer for selected processes and, tooling development / management. Recommended suppliers to improve cost and quality issues. Collaborated with suppliers and Light Speed with regard to tool designs, part consistency and processing issues. Results : Existing production part quality issues were eliminated. New concepts offered were implemented into part designs and were released with no schedule delays due to incomplete designs or non-producible features. Part quality surpassed prior designs (very important to this high-end-market supplier).
- 7. Recent Projects / Contributions Sure Power Industries, Tualatin, Oregon (Cooper-Bussman) Acquired by Sure Power to monitor mechanical development of their numerous power management products aimed at the RV, Military, and fleet-vehicle markets as well as reviewing product quality and tool-life issues with existing product. Evaluated field-related returns of existing product to assess failure mode and root-cause. Recommended solutions and measured results so assure resolution. In some cases, on-site visits at component suppliers were required to assess tool condition, maintenance records and, process methods. Assessed current Chinese die-casting sources on-site to review schedule duration and process capabilities. Dissected schedule tasks and offered suggestions on schedule improvement to the customer and assembly supplier. Provided concurrent design feedback and direction during component development (die-cast, injection-molded plastic & stamped metal parts) to assure cost and schedule were met. Contributions were in material and process recommendations, alternate designs, secondary processes, process capabilities, tooling direction and management. Educated internal procurement and development teams on Asian business practices, non-domestic part and tool development and best practices for communication and business protocol. Results : Current product quality and tool issues were corrected. New product designs were optimized to allow for reduced part and tool cost, schedule reduction and improved quality over earlier designs.
- 8. Select Projects / Contributions InFocus Corporation, Wilsonville, Oregon (Personal employer for 12 years prior to forming Technical Dimensions) 1.) LP-120 Ultra-Portable Projector: Directed 4 internal part designers (and 1 remote designer) in “Design For Manufacturability” with plastics, thixomolded magnesium and sheet metal stamping (concurrent design and development). This included material and process selection, management of all mechanical part suppliers and all tool and process development (38 tools). Also acted in a “hands-on” design capacity with several sub-systems of the product. Result : 4 personal (sole-designer) mechanical design patents were granted. No schedule slippages were seen due to incorrect part designs or improper material selections. Developed capabilities with 2 suppliers that previously were not available. Cost and quality targets were surpassed for both tooling and components. Reduced the overall development schedule by 20%. Note: This was an multiple award-winning, leading-edge product that pushed the small size envelope much further than previous efforts.
- 9. Select Projects / Contributions InFocus Corporation, Wilsonville, Oregon 2.) “777” Home Theatre Projector: This product was designed by an external partner in Asia who ultimately produced tooling, production parts and the final assembly. InFocus directed the product architecture and (via my position) monitored the part design and tool development processes. InFocus was the owner / recipient of all production tooling. Result: $700K reduction in tool costs from those proposed by the partner development company. This was a direct result of reviewing all final part designs and making cost decisions according to part complexity, material, part size and, tool type and design. The sum total of these figures was compared to those from the partner ($700K delta) and used as a means for the $700K cost reduction. 3.) Transfer of projector manufacturing from Malaysia to China: Directed the transfer of over 250 molds, casting dies, stamping dies and related processes, fixtures, jigs and gages to new sources in China. This included directing existing suppliers, freight sources, documenting process specifics, tool condition, part status and tool details for transfer into China. After arrival, on-site tool tests, FAI and Cpk studies and part analysis were directed at each source to bring production back on-line as quickly as possible without circumventing part and tool quality or production of parts.