Test Engineer / Process Engineer / Manufacturing Engineer

Robert Marquardt

Design - Quality - Manufacturing - Test

For more information please go to http://robmarquardt.info

Test Engineering Goals:

· Participate early on in product marketing and design to ensure DFT (Design For Test)

· Provide detailed Test Plans and Test Specifications

Provide well documented Test Equipment Hardware and Software system designs
Develop Low cost, High speed, High quality, Bullet Proof Automated and Semi-Automated solutions

Design systems to provide Field Return and Product Failure analysis
Design systems to provide Product Design Verification and Agency Certification Testing
Continuously Improve the Test Equipment Design, Documentation and Construction Process

Process/Manufacturing Engineering Goals:

· Provide Six-Sigma and Lean Project Engineering, Leadership and Counsel

· Maximize Productivity and Quality in Manufacturing and general business processes

· Quickly identify Root Causes of product and process anomalies

· Develop Low cost, High speed, High quality, Bullet Proof Automated and Semi-Automated solutions

· Participate early on in product marketing and design to ensure DFM (Design For Manufacturing)

· Encourage Continuous Improvement

Strengths:

· Troubleshooting and Problem Solving (Throw me at your biggest problems!)

· Self Starter - Learn new processes and systems quickly (Just point me in the right direction)

· Flexible - Always willing to do whatever needs to be done

· Work well with others across functions

· Always willing and able to help others with difficult problems and point them in the right direction

· Able to design Bullet Proof processes with built in training tools

Process Analysis and Process Improvement
Product Failure Analysis and Design Anomaly Identification
Software Design and Complex Systems Design

Skills:

· Development of detailed, high coverage product test plans and test specifications

· Design and programming of Production Test and Factory Automation equipment

· Remote Support of manufacturing facilities

· Statistical Process Control (SPC), Lean , Six Sigma, DFT, DFMA

· R&R and MSA studies, MiniTab

· Test Platform and Test Executive software design

· Product Software and Firmware design

· Project engineering and management

· ISO9000/ISO9001 process and procedure development and documentation

· Excellent writing and communication skills

· SAP, MS Word, Excel, PowerPoint and Access, OpenOffice

· Agilent VEE and NI TestStand for test development

· Rockwell Automation RSLogix and RSLinx used in factory automation

· AutoCAD - Electrical (some Mechanical)

· Software: C, C++, VB, SQL, HTML, HTTP, CSS, XML, TCL, Java Script, PLM51, PLM86

· ClearCase, RCS, SCCS

· Various Scripting Languages

· Operating Systems and Management: UNIX and Windows

· Systems Design and Networking

· Complex algorithm design

Experience:

Marquardt Test Systems, Hales Corners, WI. August 2010 - Present

Principal Engineer

Currently designing a simple, low cost, easy to use Test Executive product for the test industry
Learning how to design Web Sites (See http://robmarquardt.info)
Designed software to automate Internet Explorer
Designed a simple web server to add on to the Test Executive

Rockwell Automation , Milwaukee, WI. August 1993 - August 2010

Senior Test / Manufacturing Engineer

Developed Test Plans and Test Specifications per UL, CSA and IEC requirements
Designed and documented Test Equipment and Test Software
Reviewed product HW and SW design and provided inputs to ensure product testability

Analyzed product field failures
Tracked down root causes of process problems following up with timely solutions
Supported both local and worldwide manufacturing facilities

Engaged in Continuous Improvement
Designed both HiPot and Functional test equipment
Made major modifications to ladder logic on automated product handling systems

Allen-Bradley brand Products Tested:

All five MicroLogix Small (Packaged) Programmable Logic Controllers (PLC)
PM3000 and PM1000 power monitors
CompactLogix and SLC 500 modules
Color machine vision system

Major Accomplishments:

· Developed a high speed functional test for Micrologix 1000 products (19 sizes, 1 fixture, test time 20sec)

· Designed low cost standard HiPot and Functional test machines to use across multiple product lines

· Designed and developed a versatile, low cost, simple to use and Extremely Fast Test Executive tailored to manufacturing and corporate Quality Data Collection requirements (First release done in less than one week)

· Added extensive troubleshooting capability to Test Executive (Two day effort)

· Implemented Machine Vision into fully and semi-automated Test Fixtures

· Designed Part Tracking system for Manufacturing Cells to ensure each step of the process is executed in order and passes the tests for each step before shipping (viz. Make the process Bullet Proof)

· Implemented Laser Marking systems into manufacturing cells

· Developed a HiPot test algorithm to reduce test time by 25-30%

· Redesigned four complex automated test lines for transfer to South Korea in just a few weeks for each one

· Remotely supported automated test lines in both South Korea and Singapore

· Automated input into a Documentation Control System - 90% time reduction

· Improved data input into two different project accounting systems - 90% time reduction

· Automated the generation of drawing headers and revision control sheets - 10% time reduction

· Automated the generation of Purchase Orders for test equipment components - 70% time reduction

GE Medical Systems , Milwaukee, WI. 1990 – 1993

Test Engineer

Developed production Test Plans and Test Specifications per FDA, UL, CSA and IEC requirements
Designed and documented production Test Equipment and Test Software
Tracked down root causes of process problems following up with timely solutions
Engaged in Continuous Improvement

Major Accomplishments:

Designed, modified and improved X-Ray positioning and HV generator control test equipment and software
Working with a manufacturing engineer, identified a product backplane design anomaly

Designed test software and equipment using machine vision to inspect X-Ray collimator assemblies
Designed Self Teaching, Bullet Proof process to manage Test Software builds, validation, revision control and documentation (Reduced process time by 90% and training time by 75%)

GE Medical Systems , Milwaukee, WI. 1987 – 1990

Product Software Design and Development Engineer

Designed software for X-ray, C/T & MR image Diagnostic Review Station: interprocessor communications, ACR-NEMA network image data packet assembly and parsing, database and user interface

Major Accomplishments

Tracked down the root cause of a problem which caused the system networking functions to stop functioning after 70 hours of operation requiring a system restart to clear it up
Found the root cause of an apparent network software problem which turned out to be a simple ground loop in the hardware design
Quickly converted the two screen user interface into a single virtual screen so as to be part of the first product release (Originally planned for a later release)

GE Medical Systems , Milwaukee, WI. 1981 – 1987

Process Control - Quality Control - Test - Manufacturing - Industrialization Engineer

Started out as a Process Control Engineer then gradually took on all the above functions within three years
Responsible for Hard Wired Backplane, Cable and Harness Manufacturing
Responsible for Transformer, Stator, High Voltage Cable and High Voltage Coil Manufacturing

Major Accomplishments

Implemented Screen Room and Corona Discharge test equipment for HV cables
Developed a test machine for partially assembled, three phase transformers (Applied for a patent)
Improved transformer manufacturing process (Improved quality, reduced scrap by 90%, reduced WIP by 75%, lowered product cost and decreased the amount of floor space required)

Improved production flow on transformer line by 35%
Improved transformer tap lead and sheath manufacturing process (Reduced process time by 90%)
Reduced backplane test set-up time by 80%

Worked with engineering to add markings to bare boards to reduce assembly errors
Worked with engineering to change Parts Lists to use common and fewer components on over 100 products
Automated the generation of Functional Test software and NC machine programs along with FDA required documentation - 90% process time reduction
Developed software to optimize and batch harness wire processing. Reduced setup time by 60% and Increased productivity by 15%
Converted above software to run on remote high speed computer to reduce software execution time by 90%
Implemented SPC to identify NC machine problems and operator training needs. Resulted in improved quality and a reduction in Quality data generation time by 90%

GE Medical Systems , Milwaukee, WI. 1980 – 1981

Contract Electronics Technician (part time senior year of college)

Duplicated a complex test machine for a C/T imaging film cassette handler

Allen Bradley Co , Milwaukee, WI. 1977 – 1980

Manufacturing Line Troubleshooter (summer 1978)

Provided manufacturing troubleshooting for five automated Contactor/Motor Starter lines and the control cabinet assembly lines

Major Accomplishments

Traced a chronic cabinet assembly problem down to a tolerance overlap in the design (This affected every steel cabinet in production)
Tracked down the root cause of another chronic assembly problem which posed a potential product safety issue on the fiberglass cabinet line (Turned out to be another design tolerance overlap)

Inspector (summer 1977,1979, then half time fall 1979-spring 1980)

Performed mechanical inspection on machined parts (automatic turret lathe dept), holes and taps (drill press dept) and surface grinds on aluminum castings
Used Vernier Calipers, Micrometers, Dial/Plug/Thread Gauges, Height Gauges and Optical Comparators

Miscellaneous , Milwaukee, WI. 1980 and earlier

Inspector/Draftsman for a custom lighting manufacturer (sheet metal fabrication)

Parts Department Manager and Building Maintenance Man for a mobile personnel lift maintenance facility

Implemented parts department, developed procedures
Learned auto mechanics, welding, painting, pipe fitting, general building maintenance, HV insulation concepts (1.2Mv), personnel lift operation (up to 150ft), fork lift operation, hydraulics, Magnaflux, truck driving (up to 35ton) and snow plowing

School/Charter Bus Driver

Education:

Training, Seminars, Short Courses and Self Study 1980 – 2009

· Lean Manufacturing, Six Sigma, Green Belt

· Design For Manufacturing and Assembly (DFMA)

· Statistical Process Control (SPC), Short Run SPC

· Kepner Tregoe, Zenger Miller (Problem Solving)

· Yourdon Structured Design and Analysis

· Product Liability and Prevention

· Quality Leadership

· Numerous software courses

· Lock Out – Tag Out (LOTO)

· Electrical Safety – Contact (Certified)

· CPR, LifeSaver AED (not current)

· HAZCOM

· Fire Extinguisher

Milwaukee School Of Engineering , Milwaukee, WI. 1976 – 1980

Bachelor of Science in Electrical Engineering (BSEE)

Elective Courses:

Calc I, Calc II, Calc III, Differential Equations, Fourier Transforms, Laplace Transforms
Numerical Methods, Statistics, Statics, Dynamics, Thermodynamics
Inorganic Chemistry, Organic Chemistry, Modern Physics
Logic, Transmission Lines, Antennas, Solar Energy, Internal Combustion Engines
Motors and Transformers
Latin & Greek Word Roots, US History, Human Factors

Franklin High School, Franklin, WI. 1971 – 1975

Focused on electronics

Elective Courses:

Electronics (4 years), Chemistry, Physics, Algebra, Geometry, Trigonometry, Calculus
Woodworking, Photography, Journalism, Writing, Private Pilot course

Philosophy:

· Strong believer in Quality Control and Process Optimization to make manufacturing businesses successful

· Firm believer that America can still be the world leaders in manufacturing

· Follower of W. Edwards Deming's Quality principles

· Greatly influenced by Taiichi Ohno and the Toyota Production System

· I take Continuous Improvement very seriously

· "It Can't Be Done" is NOT in my vocabulary - I take that statement as a challenge

Favorite Quotes:

"The combination of phenomena is beyond the grasp of the human intellect. But the impulse to seek causes is innate in the soul of man. And the human intellect, with no inkling of the immense variety and complexity of circumstances conditioning a phenomena, any one of which may be separately conceived of as the cause of it, snatches at the first and most easily understood approximation, and says 'Here Is The Cause'."

- Count Leo Tolstoy, "War and Peace", Part XIII, I

- Found on inside cover of Deming's "Out of the Crisis"

"Read every day something that no one else is reading.

Think every day something no one else is thinking.

It is bad to be always a part of unanimity." - Christopher Morley

"We have done so much with so little for so long that we are now qualified to do anything with nothing in no time at all." - Author unknown (probably an engineer)

"Never, Never, Never Give Up!" - Sir Winston Churchill

Hobbies:

Auto/Motorcycle Mechanics
Woodworking
Fixing just about anything

Contact Information:

Robert A. Marquardt

6231 So. 116th St.

Hales Corners, WI. 53130

(414) 425-7255 (home )

(414) 418-8951 (mobile 1)

(414) 350-9327 (mobile 2)

E-mail:

Please see Web resume' at http://robmarquardt.info , click Information on the left bar then click Resume'