Eaton Aerospace Introduction 

All images above are from www.eaton.com and public images 

Eaton Aerospace located in Glenolden Pennsylvania, near the Philadelphia Airport. This facility specialize in fluid debris collection and monitoring.

A high mix low volume manufacturing facility, with machine shop and product assembly. 

Products: 

• Lubriclone®
  • Air/Oil Separators 
  • Sensor Port & self closing for QDM®
• Quantitative Debris Monitoring Systems (QDM®)
  • Active ferrous debris monitoring 
  • Sensors with connectors or cables
• Signal Control Units (SCU) 
  • QDM to aircraft Full Authority Digital Engine Control (FDAC) communication device
• Electromesh® 
  • Sensor to indicate the presence of conductive, non-ferrous debris particles
• Electro Optic Sensor (EO) & Floats  
  • Fluid Detection or level sensor 
• Chip Detector & Zapper® 
  • Ferrous debris collection indicator & material eliminator 
• Chip Collector & Self closing Valves/Screens
  • Magnetic plugs to collect ferrous debris 
• Sight Gauges & Plugs 
  • Visual oil monitoring systems & accessories 
    
    

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Roles & Responsibilities 

Lead Manufacturing Engineer (2015-2022)
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Primary Roles

• Automation & Machine Design Specialist
• Industry 4.0 Engineer
• LabVIEW Automated Test Stand Developer
• Production Line Manufacturing Engineer
  • Chip Collectors & Mechanical accessories
  • Lubriclone®
• Project coordinator for manufacturing capability transfer to Bangalore India

Secondary Roles 

• Part of division Additive Manufacturing, Connected Work Cell, and Co-Bot Councils
• Site champion for IPC-J-STD-001E Ionic Cleanliness 
• Site champion for Lock-Out Tag-Out 
• Automated Optical Inspection (AOI) Machine process developer & programmer (Assembled PCBs, Through hole & SMT)
• CNC Programmer (MasterCAM) & CNC Operator  
• Manual Machinist (Manual Mill & Lathe) 
• Drexel Senior Design Engineering Sponsor (3x groups) 
  • Automated Rolling & Robotic dispense of adhesive

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Notable Accomplishments 

Root cause analysis to reduce electronic noise in sensor 
➤ Estimated 200k in cost savings from determining the problem and fixing the issue

➤ Developed innovative technology for automated vacuum degassing of small batch potting materials 

Deployed major LabVIEW automated test stands and manufacturing tools 
➤ Tools helped to remove operator error in automated final testing, laser marking duplication, and government audit data collection 

Deployed & integrated site's first Semi-Automated tool cell that optimized long standing processes
➤ Designed Rotatory Bench for single piece flow assembly of Chip Collectors 
➤ Developed Automated Drilling Machine for pin holes; removed skilled manual process 
➤ Developed Semi-Automated test sink for proof pressure testing; stream lined bottleneck and improved operator ergonomics 
➤ Manufacturing optimization netted $100k in cost savings and reduced production time by 1/3. ​

Working with International team to share knowledge and mirror production at a new Eaton facility in Bangalore India 
➤ Balanced project management, teamwork, strategic schedules, manufacturing education & training

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Automation & Machine Design Specialist - Continuous Improvement (CI) & Manufacturing Engineering Group 

• Site expert for LabVIEW Programing
  • Deployed, optimized, and maintained automated test stands
• Developed in-house technologies for solving manufacturing issues  
  • Automated Vacuum Degasser
  • Used process capability studies to ensure quality
• Practiced Lean Manufacturing
  • Rapid Improvement Events (RIE) 
  • Value Stream Mapping 
  • Standard work & Balance sheets
  • 3P & PQPR 

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Industry 4.0 Engineer - Manufacturing Engineering Group 

• Worked with Omron TM5-700 Collaborative Robot (Cobot) 
• Developed smart connected work cells (CWC) 
  • Smart Tools 
  • Digital Work Instructions (DWI) using PTC Thing Worx 
• Electro-Mechanical and PLC design for internal integrated projects
  • Proof pressure oil test machine 
  • Button operated rotameter flow diverter

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Production Line Manufacturing Engineer 

• Process improvements & Cost-out
• Manufacturing Instructions & Routes
  • Standard work 
• Product Troubleshooting & rework
• Time studies 
• Fixture/Tooling design & manufacturing 
  • Experienced with CATIA V5 & AutoCAD
  • Designed tools to be made by in-house machine shop and/or individual machining 
  • Utilized 3D printing for majority of fixtures 
    • Stratasys uPrint SE (ABS Plastic) 
    • Markforged Mark 2 (Nylon, Onyx) 
    • MakerGear Ultra One (ABS, PLA, ESD Safe) 

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Project coordinator for manufacturing capability transfer to new Eaton site in Bangalore India 

• Will move four product lines over 3 year period 
• Utilized Microsoft Teams to share information between sites 
• Use of OneNote for meeting tracking
• Utilized HoloLens 2 for knowledge transfer and operator training