The Vice President of Operations has the overall responsibility for leading the manufacturing and engineering functions. He/she is responsible for improving and maintaining the processes necessary to manage capacity and demand in dynamic engineering and manufacturing projects, emphasizing streamline operations and reducing costs. The individual is responsible for improving communication across the organization, working with the president, sales team and project managers to manage customer expectations for optimal long-term profitability.

Qualifications:

1. MS/BS in Mechanical Engineering, Industrial Manufacturing, Business Administration or related area.
2. Twenty years experience in a manufacturing company, including experience in custom manufacturing (job shop) with large, highly engineered systems or equipment.
3. Ten years demonstrated effective utilization of lean techniques to identify opportunities and execute improvements.
4. Five years of experience managing engineering.
5. Must be assertive, driven to achieve results, and a proven motivational leader.
6. Must have a proven track record of developing the staff, creating a team environment, and leading change within an organization.
7. Requires strong business and financial acumen and strong communication skills.

Performance of duties as a Senior Controls Engineer requires knowledge of an advanced type in a field of science or learning customarily acquired by a prolonged course of specialized intellectual instruction and study. Performance of the work requires consistent exercise of discretion and judgement to design and develop machine controls hardware and software in conformance to customer specifications employing standard design practices, applicable codes and assessment of functional requirements.

Qualifications:

1. Education and/or Experience:

• BS Degree in Electrical Engineering or equivalent technical degree or equivalent experience. A minimum of seven years experience in controls design.
• At least one area of machine controls expertise, such as robots, vision, servos, communications, data networks, computer languages, or a manufacturing process such as metal cutting.
• Experience as a member of a team. This requires being supportive of team, department and company goals and practices.
• Extensive experience with one of the major PLC brands (AB, GE, Modicon, etc.) and exposure to other brands of PLC.
• Knowledge of PLC networking systems (Data Highway, Modbus, etc.).
• Proficiency in the use and application of test equipment such as; multi-meters, analog and digital oscilloscopes, chart recorders, data acquisition systems, leak test systems, flow measurement systems.
• Knowledgeable in the design and application of fluid power (hydraulic, pneumatic,vacuum).
• Proficient in the use of IBM-compatible computer, Operating Systems (DOS, Windows), word processor, spreadsheet.
• General knowledge of at least one computer language (Basic, C++, Fortran, Assembler. etc.).
• Thorough knowledge of appropriate regulations, specifications and codes (customer specifications, NEC, NFPA, JIC, ANSI, OSHA).
• Awareness of IEC specifications.
• Thorough knowledge of documentation practices drawing sets, structure, CAD issues, PLC and PC programming software, bills of material.
• Thorough knowledge of power distribution as it applies to machine control.
• Thorough knowledge of electro-mechanical power control ( contractors, starters, relays).
• Knowledge of electrical  noise control through panel wiring design.
• Knowledge of heat dissipation calculations and control for electrical panels.
• Exposure to machine drive systems, servos, steppers, drives, indexers.
• Exposure to machine vision systems.
• Exposure to robotic systems.
• Familiarity with manufacturing processes.

1. Language Skills:

• Ability to read, write, and verbally communicate instructions and other correspondence to internal and external customers and associates.

2. Mathematical Skills:

• Ability, and knowledge to do electrical calculations required for proper design of machine electrical system. Knowledge of heat dissipation calculations and other related calculations for power requirements, etc.

3.  Reasoning:

• Ability to understand and participate in resolution of issues relating to controls design.

4. Certificates, Licenses, Registrations:

• This position has no requirements for certificates, licenses, or registrations at this time.

The Senior Design Engineer studies product blueprints, manufacturing processes, and/or customer specifications to conceptualize the machine design required to produce the product.  Using knowledge of machines, machining, and manufacturing processes, the Senior Design Engineer creates drawings for accurate interpretation of the design by toolmakers and oversees the auxiliary layout and detailing activities.

QUALIFICATIONS:

1. Bachelor’s degree in mechanical design, engineering or related area OR at least six years mechanical design experience.
2. Thorough knowledge of machine tools and assembly of special machines.
3. Application of mechanics, hydraulics, pneumatics, and manufacturing machinery.
4. Understanding of costs and production times to manufacture machinery.
5. Experience in computer aided design
6. Applied math skills using geometry, trigonometry, and standard tool engineering data to develop machine configuration.
7. Experience interpreting specifications, blueprint and engineering data.
8. Demonstrate creativity and ability to make decisions and meet deadlines
9. A demonstrated organized, sequential and practical approach to design is desired.

The Machinist sets up and operates conventional, special purpose, and numerical (NC) machines and machining centers to fabricate metallic and nonmetallic parts, and fits and assembles machined parts into complete units, applying knowledge of machine shop theory and procedures, shop mathematics, maintainability of materials, and layout techniques.

QUALIFICATIONS:

1. Between 4 and 10 years of trade school, vocational education, work experience, and/or apprenticeship.
2. Ability to perform math calculations using trigonometry.
3. Familiarity with geometric dimensioning and tolerancing.

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DTE recognizes that time to market is a critical factor for the successful introduction of Pharmaceutical products. The packaging operation in manufacturing is often one of the obstacles to fast product introduction especially if standard equipment cannot be utilized. DTE has provided customized pharmaceutical packaging lines which enabled our customers to get their products to market ahead of their planned product introduction timeframe.

System Overview

DTE can provide customized packaging lines which consist of standard thermoforming and cartoning equipment in combination with our custom material handling and vision inspection systems. For the packaging of an oral drug delivery device, DTE provided a packaging line consisting of a robot for populating blisters, a thermoformer, vision inspection systems, a robot for blister transfer and a cartoner. The system was shipped 8 weeks ahead of schedule and the user exceeded production schedules within 3 weeks of installation. A second system was provided in the following year and it was operational 3 days after user site installation.

System Highlights

• Custom part feeding equipment
• Custom gantry robot for product feeding
• Vision inspection system for lot and date code
• Standard horizontal blister forming machine
• Vision inspection system for product quality
• Multi color printing system
• Blister accumulation system
• Blister inversion, rotation and nesting
• Standard automatic cartoner
• Automatic instruction leaflet insertion
• Automatic weight checking
• Metal detection feature
• Optional case packing & palletizing
• Allen Bradley Controllogix Platform

System Values and Benefits

• High Output-Up to 300 parts per minute
• Product changeover in less than 15 minutes
• Tamper proof carton packaging
• Bar code verification Product inspection
• Uptime greater than 98%

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Copyright 2011 Detroit Tool & Engineering

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Detroit Tool & Engineering was a single source for the tooling, special forming and welding equipment for this Oven project. This is only one of many projects where DTE has combined the tooling and the special machines to give the customer a one stop shop. DTE can control the total schedule of the project, providing fit up parts to the machine group as required, part development utilizing tooling and machines with no shipping of part between two suppliers.

System Overview

• Single source for total project control
• Tooling group supplied parts for the equipment development and run off
• Tooling group utilizes Dynaform software for drawn part die design
• Machine design utilizing information from tooling

System Highlights

• Tooling package included twenty dies for the one project plus eight additional for other parts.
• One special machine to final piercing of different hole pattern, One to form a reverse curl complete in the opening and one to spot weld all parts together including two additional parts.

System Values and Benefits

• Mid-freq. welding with servo controlled locations
• Tooling design for automated press line including part transfer with auto die change
• Matching shut height for all tooling
• Matching clamping locations for all tools
• Cell configuration layout for lean manufacturing

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Copyright 2011 Detroit Tool & Engineering

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This project represents the first phase of several projects in which DTE worked with our customer to take multiple sizes of different parts of construction equipment and give them the ability to weld the parts together on a single fixture. This project paved the way for additional orders from our customer for new fixtures or modifications to current fixtures when models change or new models have been added to the program. Our constant communication through our project team members and quality that surpassed our customers’ expectation has benefited DTE by giving us the opportunity to expand the work we do for this customer into other areas of the manual weld, machining, and robotic weld departments.

System Overview

• The overall program consists of twelve different weld fixtures.
• Each fixture can accommodate an average of three or four different models.
• Part tolerances on some fixtures range as low as .020″.
• Overall fixture sizes range from approximately 3 feet long to approximately 20 feet long.
• Efficient storage of change out parts was a requirement in order to maintain a space saving solution.

System Highlights

• Solutions to control deformation caused by the weld process are implemented on each fixture.
• Individually controlled hydraulic valves assist with movement on larger weld fixtures or with parts that cannot be moved manually.
• Coordinated change out parts with locators which were utilized to ensure correct positioning for each different model.
• Movement of different parts on a fixture to accommodate a different size model is achieved with slides that lock into place with plunger style locators.
• Custom designed racks provide efficient storage of change out parts in close proximity to each fixture.

System Values and Benefits

• Combining multiple models on a single weld fixture reduces the overall required floor space.
• Precision locating eliminates the need for manual measurement of parts throughout the weld process.
• Coordinated change out parts allow for quick change between models.

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Copyright 2011 Detroit Tool & Engineering

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Ever increasing transmission rates for data forced all telecommunications equipment manufacturers to constantly upgrade and redesign their products to adapt to the market needs. This manufacturer of high speed data ports teamed up with the Bodine technical group while the product was still somewhat fluid, allowing them to take advantage of the “Design For Assembly” expertise that was available. The new connector needed to be assembled at high speed, and with great precision. Contact wire forming and positioning within the housing was absolutely critical to the functionality of the product. This made the Bodine Chassis the ideal platform.

System Overview

The system would be made up of three modules: On the PCB (printed circuit board) Module, (8)IDCs (insulation displacement contacts) are processed and inserted into zero clearance holes in the PCB. Additionally (2) sets of precision formed wire lead frames are pressed into the PCB. The Solder Module uses a thermal carrier puck on a conveyor system to send subassemblies through the solder reflow oven. The Final Module allows the soldered PCB to be assembled into its plastic housing. Labeling, ultrasonic welding, final wire form die cutting, and functional electric testing all follow with good assemblies being laser marked.

System Highlights

• System Operating Speed :50 ppm
• Gross Production Rate : 3000 assemblies/hour
• High Precision Placements Prevent Wire Damage
• Vision Verification of All Critical Placements and Dimensions
• Components are Fed from Coil Stock, Die Cut and Transferred.
• Protective Puck Pallets used in Solder Process.

System Values and Benefits

• Standard platform ensures proven performance results.
• 100% vision verification of critical features.
• Quick change mounting for Die sets to allow for minimal downtime to facilitate die maintenance.

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Copyright 2011 Detroit Tool & Engineering

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Detroit Tool and Engineering designs and builds continuous motion machines for a variety of applications. The most common applications are the closing of plastic molded caps and the assembly of two piece caps. Continuous motion design is also applied to other applications such as: Pharmaceutical Product assembly at 250parts per minute; Confectionary Product packaging at 200 PPM; and others.

System Overview

The Model 938 Cap Closing Machine is a rotary, continuous motion machine which closes hinged plastic caps from the open position. This design achieves cycle speeds up to 400 parts per minute, depending on cap size and shape.

The Model 937 Two-Piece Cap Assembly Machine is a mechanically synchronized rotary machine to assemble two piece caps. Cycle speeds of up to 450 parts per minute can be achieved depending on cap size and shape.

System Highlights

• Speeds up to 450 parts per minute
• Cam controlled continuous motion using from 6 to 24 spindles depending on product configuration
• Mechanical Overload protection safeguards the machine
• Detection and subsequent rejection of missing or not fully closed lids
• Variable speed D.C. motor to adjust speed to match associated process machines
• Automatic machine stop after a predetermined number of rejects is reached

System Values and Benefits

• Low Maintenance Cam controlled design
• Mechanical Overload protection for safety
• Reliable detection and removal of missing lids or not fully closed lids
• Resettable product counter with diverter gate for box packaging options

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Copyright 2011 Detroit Tool & Engineering

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A large medical product design firm has determined that it will introduce a new “safety” Catheter to the marketplace. This is in response to legislation and a market recognition of the need for medical products which do not threaten the health care provider with undo risk of infection. The Catheter’s design incorporates a protective sheath and a retractable needle (Cannula), insuring that the individual introducing the Catheter into the patient’s vein, does not accidentally get stuck by an infected device. The risk of HID, Hepatitis C, etc. have created the need for such medical product redesign. The safety features result in a more complex assembly process with more components than a standard traditional Catheter.

System Overview

The entire product was assembled on one Bodine indexing carousel assembly module. Bodine was selected because the customer knew of Bodine’s experience with Catheters and the related assembly processes. The assembly module was 9 bays in length, providing 54 possible operating stations, 42 of which were actually used in this case. The product consisted of 9 components and (2) different gages of Cannula had to be handled. Operating at 30 cycles per minute, the system had a gross production rate of 1800 assemblies per hour. The system was operated in a class 10,000 clean room. Extensive use of sophisticated vision systems assured Needle grind quality and ultimate Cannula radial orientation.

System Highlights

Assembly process highlights included:

• Auto cannulas loading, adjustable to two different gages (see photo)
• Automatic feeding of all components
• Extra space on machine to accommodate future product variations
• UV curing of Loctite adhesive (used to glue Cannula to Hub) PLC based control system with remotely monitored HMI and Webnet remote reporting system
• Lubeless clean room tooling
• Full verification of all assembly processes and critical dimensions
• Automated bagging of finished product prior to final sterilization process.

System Values and Benefits

• Clean room operation
• Fully automated assembly process…no human contact during assembly
• High production volumes…gross production rate of 14,400 assemblies per 8 hour shift!

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Copyright 2011 Detroit Tool & Engineering