Product Development Executive
Product Development Leader with 20+ years of Research & Development (R&D), Intellectual Property (IP) development, Engineering Design & Management, CAD, CAE, Mechanical Design, Prototyping and Production Manufacturing. Expertise with hardware / physical products and system integration. Strong background in early-stage ideation, proof of concept & minimum viable product development through to manufacturing and supply chain development phases in start-up environments as well as working in collaboration with Fortune 100 and multinational companies such as Ford Motors, The Boeing Co., Raytheon, Lockheed Martin, BAE Systems, Toyota, and Yamaha.
Professional Skills
Product Development ~ Portfolio Management ~ Program Management ~ Competitive Intelligence ~ Intellectual Property ~ Business Development & Management ~ Financial Management ~ Operations Excellence ~ Organizational & Process Development ~ Mechanical Engineering ~ CAD & CAE ~ Prototyping ~ Manufacturing Processes ~ Design ~ Innovation / Design Thinking
Accomplishments
Research & Development:
• Developed an actuated, semi-robotic lifting arm for integration into the DARPA (Defense Advanced Research Projects Agency ($33M) HULC (Human Universal Load Carrier) exoskeleton system. Provided a functional POC (Proof of Concept) prototype that enabled primary contractor Lockheed Martin to meet Critical Design Review milestones and secure next phase funding. Delivered project on time and on budget in under 4 months.
• Designed and led a joint venture program with Ford Motors, The Boeing Company and Virginia Tech University to study the ergonomic benefits of a body worn arm assist device to reduce upper extremity musculoskeletal workplace injuries Aerospace and Automotive manufacturing assembly lines
• Co-authored an NIH SBIR (National Institutes of Health Small Business Innovation Research) proposal as Principal Investigator to study the use of semi-robotic assistive human arm support technology as a therapeutic modality to improve upper extremity neuroplasticity.
• Led early-stage research and proof of concept prototyping of a novel form of rotor for marine and air propulsion. Outcomes included development of a parametric modelling methodology and geometric definitions enabling IP disclosure and successful patent awards. Delivered fundamental proof of concept development to provide the technology validation needed to successfully pursue funding for further development.
• Led the design and development of a clinical trial testbed device used to evaluate efficacy of a novel approach to preventing DVT (Deep Vein Thrombosis) in non-ambulatory post-op patients. Completed the project 25% ahead of schedule and at 50% of the budget.
• Designed and implemented a modular feature system for investment casting pattern production that improved casting quality by solving a gating problem and reduced fixture set up and machining time by 25% and improved final part surface finish and accuracy.
Operations Excellence:
• Launched and operated all aspects of a NPD (New Product Development) sub-unit, providing mechanical engineering R&D for the parent company. Responsible for all aspects of start-up operation from facility acquisition, office space and fabrication shop build-out to recruiting and employee development, and setup of all business functions.
• Owned NPD releases, departmental budgets and forecasts. Implemented engineering design methods and processes, data management SOP’s, and prototyping iteration workflows. Designed and deployed a structured verification and validation Stage-Gate process for preliminary and critical design reviews, change & quality management.
• Developed professional services sales strategy and process, engineering data infrastructure, implemented policies required to meet certifications and registrations required to pursue sub-contracted service and supply agreements with Gov. and Mil. Contractors.
• Developed, resourced and launched an outsourced financial team to provide accounting, reporting and controller functions for a rapidly growing company, enabling board level reporting and performance visibility. Built a comprehensive 5-year business forecast model that included all associated Capex, CGS reductions, Departmental Budgets and cash requirements to scale from $0 to $65 MM revenue.
• Led the process to identify and right sized MRP tools and the customization and adoption of cloud-based CRM platforms (experience with Salesforce and HubSpot) with various back-end integrations.
• Set up a multi-node supply chain for rapid, hi-mix low volume complex investment cast and machined parts for beta production that transitioned to scalable volume rates with the development and integration of automated finishing operations.
Product Launch:
• Sharrow Propeller; Marine propulsion, from concept to manufacturing and retail and OEM sales. Lead Professional Services, established sales processes as direct customer liaison and account manager.
• SkyCam® Broadcast Camera System; Led a team of ME’s, EE’s, software developers, technicians and contractors in an 8 month $1.2MM platform redesign program.
• Steadicam ® & Merlin Camera Stabilizers; Designed & delivered mechanical engineering, and industrial design of three models of Hall of Fame Inventor Garrett Brown’s Oscar winning Stabilizers, reducing parts count by 200%, assembly time by 300% and providing significant reduction of CGS (Cost of Goods Sold) and improving performance, reliability and usability. Merlin handheld stabilizer: Industrial Design and co-inventor patent awarded for the Folding and Adjusting Hinge for Stabilized Equipment support.
• ZeroG Industrial Ergonomic Support Arm; Designed & launched two industrial tool support platforms for use in automotive, aerospace and MRO industries to eliminate worker fatigue and repetitive stress injuries and improve quality and productivity by reducing accidental product damage.
• X-Ar; Human Arm Support: Launched in two markets as an upper extremity assistive device, for use by industrial workers, and by persons with musculo-skeletal disabilities to enable activities of daily living.
Patents
Loop Stator for Vessel Propulsion Systems, 63/413,860 Prov. App. October 2022
Modular Propeller Diffuser System, 63/309,898 Prov. App February 2022
Biased Hinge, US 10240376 B2 Awarded March 2019
Exoskeleton Arm Interface, US 9719633 B2 Awarded August 2017
Multi-Arm Gimbal System, US 9534730 B2 Awarded January 2017
Gimbal Assembly for Tool Support, US 9156154 B2 Awarded October 2015
Concentric Ring Gimbal Support System, US 8827216 B2 Awarded September 2014
Human Support System, WO 2013003369 A3 Prov. App. May 2014 (inactive)
Equipoising Support Equip. Biased Hinge, US 8801319 B2 Awarded August 2014
Optical Device, US 8192014 B1 Awarded June 2012
Combination Support System, WO 2012027433 A1 Prov. App. March 2012 (inactive)
Folding & Adjusting Hinge Equip. Support, US 7625090 B2 Awarded December 2009
Reading Glasses, US 6705720 B2 Awarded March 2004
Employment
Sharrow Marine, R&D, Product Development, Sales Detroit, MI / Philadelphia, PA
Director of Research and Development & Professional Services Nov 2021- Present
V.P. of Product Development / Director of Operations May 2018 – Oct. 2021
Consulting Design Engineer April 2014 – Feb. 2016
• Initially engaged as a Product Development consultant to provide very early-stage proof of concept work, turned in to an 10+ year relationship as the technology and company evolved from a boot-strapped project to a B-Round $30M startup, now generating revenue.
• Managed development and design of a novel fluid propulsion device and produced an outboard propeller that won the 2020 NMMA Innovation award for marine propulsion.
• Built out startup operations and processes including scheduling, consulting engagements, and HR processes, design reviews, product releases, testing, and validation.
• Created and maintained development processes; data management, configuration and iteration tracking workflows resulting in a continuously improving rapid prototyping cycle with ongoing optimized engineering processes to adapt to the shifting requirements of start-up evolution. Resulting in scalability, readiness for growth, transparency, and implementation of best practices and SOP’s.
• Developed and managed supply chain of foundries, machine shops, finishing suppliers. Managed logistics, vetted supplier capabilities, initiated and managed purchasing and QC processes and MFG releases.
Archimedic Medical Device Development, Director of Mech. Engineering Philadelphia, PA 2017 – 2018
• Senior point of contact for clients. Analyzed client needs, identified key objectives, created proposals, generated billings, planned designs and scope, led ideation sessions, tested prototypes, and developed product design solutions.
• Met consistent month over month team resource utilization target levels of 78%-85%.
• Implemented a design history tracking method focused on client project transparency which improved the capture, depth, and clarity of client information delivery and project profitability by 15%-25%.
• Learned the role of FDA Regulatory (FDA 21 CFR 820) and Medicare reimbursement policy in medical device development. Authored IRB for clinical research prototype testing for UPenn venture funded research program.
• Projects included: Picosecond Laser Corneal Ablation for Astigmatism, a clinical trial device for Deep Vein Thrombosis Prophylaxis, prototyping for pre-clinical trials of an Implantable Lymphatic Pump System for heart disease treatment, Pre-Clinical Prototypes of Cannula and IV fittings for an Artificial Uterus, and a Wearable Aroma Therapy Device for health care workers.
Equipois Inc., Industrial Exoskeleton Los Angeles, CA / Philadelphia, PA
V.P. of Technology, 2009 – 2013
Director of Product Development 2007 – 2009
• Owner of Product Design, R&D, platform architecture, and technology IP roadmaps as the first hire of a 22-person $13m venture-funded startup with exclusive license of the Steadicam technology for use in industrial applications. Achieved MVP in 6 months. Successfully delivered products to target markets in automotive and aerospace manufacturing, in 18 months.
• Led the NPD team in the design testing and manufacturing development of three mechanical arm system platforms for tool holding applications. Designed and led development of the X-Ar Human Arm Support system for persons with disabilities, oversaw industrial application trials in several manufacturing industries and supported premarket human trials for use by patients with upper extremity musculoskeletal disorders.
SkyCam / CF InFlight Philadelphia, PA
Director of Engineering & Industrial Design 1999 – 2003
SkyCam Camera System: Led software, mechanical engineering and electrical engineering teams in the complete redesign and conversion of all systems from analog to current digital state of the art and still famous cable suspended camera system in use today for live NFL broadcast and other events.
Awards & Recognition
NMMA Innovation Award Awarded March 2020
Wall Street Journal Technology Innovation Awards Awarded October 2011
Britweek UK Trade & Investment Business Innovation Awarded May 2011
Patrick Soon‐Shiong Innovation Award Awarded November 2010
Stevie Award, Innovative Company of The Year, N. America Awarded July 2010
Education & Associations
Penn State University, Engineering & Earth Sciences, 4 years
Pennsylvania Academy of the Fine Arts, 4-year Certificate (BFA equivalent)
MIT Sloan School of Business, New Product Development Executive Training Seminar
American Society of Mechanical Engineers (ASME), Member
Product Development Management Association (PDMA), Member