Alan E. Smith

Precision components manufacturer · Current employer, name withheld

• Lead manufacturing engineering while staying hands-on: process development, tooling and production support, working directly with operators.
• Manually program Swiss-type lathes on Fanuc 0i, 30i and 31i controls, and develop and troubleshoot complex Swiss-turned parts at the machine. Have run Citizen, Star and Maier Swiss lathes.
• Program and run hard turning of tool steel at 60 to 65 HRC.
• Engineer tooling for medical, injection-mold, ammunition, aerospace and battery applications, routinely to 0.0005 in. and as tight as 0.0002 in.
• Produced tooling for the manufacture of D, C, AA and AAA cells for a major consumer battery brand.
• Program in Mastercam, design in SolidWorks, and modify Mastercam post processors for specialized equipment.
• Administer and troubleshoot Infor Visual ERP (since 2008, through Visual 10): work orders, costing, scheduling, MRP, inventory, reporting, users and security.
• Write and maintain SQL Server queries, views and reports daily; reconcile data, manage backups, and diagnose locking and blocking with Extended Events.
• Built scheduled Python jobs that keep items, orders, manufacturing orders, BOMs, routings, shipments, invoices, lots and serial numbers in step between two ERP systems.
• Planned and personally built the 2013 plant CAT6 upgrade: specified the hardware, terminated and tested every run, and added a second rack about 250 ft away on a fiber backbone.
• Run plant IT: Windows Server, Active Directory, VMware, Microsoft 365, DNS and DHCP, SonicWall firewalls and VPN, switches, wireless, and RS-232 program transfer to the CNC machines.

Corry Manufacturing

• Developed the unfolded "butterfly" pattern from finished 3D airfoil geometry and designed the progressive die that formed it.
• Built 500+ cooling holes into the flat pattern so each landed within about 0.010 in. true position in 3D space after forming.
• Reverse engineered aftermarket replacement airfoils, coordinated outside metallurgical analysis, and compiled the technical package submitted for FAA approval before manufacture was authorized.
• Served as the on-site technical contact confirming that laser processing of an OEM customer's components stayed within its requirements, including recast-layer limits.
• Designed in Unigraphics / Siemens NX, working directly from the OEM's native models.
• Ran a 5-axis CNC YAG laser and performed recast-layer metallurgical analysis of the laser cuts.

Independent

• Reviewed EDM electrode designs and made recommendations to improve EDM efficiency.

Jamestown Precision Tooling

• Started on Mastercam Version 4, the last DOS release, in 1994 and have used it continuously since.
• Modified a Mastercam wire-EDM post to generate XY motion for a custom CNC grinder.
• Programmed a CNC ram EDM to remove material progressively with a 1/4-in. full-radius graphite electrode, reaching a feature about 6 in. deep that a milling cutter could not reach rigidly.
• Achieved a 2 µin mirror finish straight off the EDM on a component too small to polish afterwards.
• Produced bunters for ammunition headstamps.
• Wired and configured RS-232 links between CNC machines and networked computers for program transfer.

Dayton Progress

• Ground precision points on finished customer parts to diameter tolerances as tight as 0.0002 in.
• Moved from the grinder into process engineering for high-precision tooling.