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Eaton Aerospace - Glenolden PA 

Eaton Aerospace Introduction 

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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 


Roles & Responsibilities 

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Lead Manufacturing Engineer (2015-Present)
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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

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

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 
  • Elecctro-Mechanical and PLC design for internal integrated projects
    • Proof pressure oil test machine 
    • Button operated rotameter flow diverter

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) 

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

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