Technical Dimensions LLC

Technical Dimensions LLCTechnical Dimensions LLCGreg Sample, Sr. ConsultantGreg Sample, Sr. Consultant3601 Madrona Drive3601 Madrona DriveNewberg, Oregon 97132-1557Newberg, Oregon 97132-1557

T: 503-538-9244T: 503-538-9244F: 503-538-9244F: 503-538-9244M: 503-200-8245 (Domestic U.S.)M: 503-200-8245 (Domestic U.S.)M: 86-134-3402-0075 (China)M: 86-134-3402-0075 (China)

[email protected]@[email protected]@verizon.net

Mechanical & Manufacturing Development ConsultantMechanical & Manufacturing Development Consultant

Experience / CapabilitiesExperience / Capabilities

- 28 years in mechanical design; components, products, process & tool development28 years in mechanical design; components, products, process & tool development

- 24 consecutive years of Asian business experience in 8 countries24 consecutive years of Asian business experience in 8 countries

- Mid-level ability to communicate in Mandarin ChineseMid-level ability to communicate in Mandarin Chinese

- Hands-on experience in part and product design, specialist in manufacturing Hands-on experience in part and product design, specialist in manufacturing processes, tooling and material selectionprocesses, tooling and material selection

- Demonstrated success directing mechanical design teams, product development Demonstrated success directing mechanical design teams, product development teams, quality assurance departments, suppliers, transition of products into teams, quality assurance departments, suppliers, transition of products into manufacturing, tooling development and, tool and process transfers to new suppliersmanufacturing, tooling development and, tool and process transfers to new suppliers

- National and International design awards in die-casting, injection molding and National and International design awards in die-casting, injection molding and ThixomoldingThixomolding

- Numerous personal and team patents for component and process designsNumerous personal and team patents for component and process designs

- Proven ability to innovate, reduce costs, improve quality and reduce scheduleProven ability to innovate, reduce costs, improve quality and reduce schedule

Consulting ServicesConsulting Services

- Concept BrainstormingConcept Brainstorming

- Risk / Cost / Quality Assessment of designs and conceptsRisk / Cost / Quality Assessment of designs and concepts

- Component Design Assistance: (Design for Manufacturability, Design for Assembly)Component Design Assistance: (Design for Manufacturability, Design for Assembly)- Cost and quality optimization of new and existing partsCost and quality optimization of new and existing parts- Material and process selectionMaterial and process selection- Concurrent development with client design teams to eliminate serial feedback from supplier and impacts to Concurrent development with client design teams to eliminate serial feedback from supplier and impacts to

schedule and costschedule and cost- Manufacturing process developmentManufacturing process development- Assessment / analysis of existing partsAssessment / analysis of existing parts- Redesign of existing parts / Alternate design conceptsRedesign of existing parts / Alternate design concepts- Research new materials and processesResearch new materials and processes- Specification reviews, recommendationsSpecification reviews, recommendations

- Schedule Development: Component Design & Cost, Tool and Process, ProjectSchedule Development: Component Design & Cost, Tool and Process, Project

- Supplier Evaluations / Risk Assessment / Recommendations / Management / On-site visitsSupplier Evaluations / Risk Assessment / Recommendations / Management / On-site visits

- Manufacturing Tooling:Manufacturing Tooling:- Provide direction to suppliers or procurement teams during the RFQ processProvide direction to suppliers or procurement teams during the RFQ process- Tool design review to assure quality, life and cost targets are metTool design review to assure quality, life and cost targets are met- Filling analysis to assure quality and schedule are metFilling analysis to assure quality and schedule are met- Management of suppliers during tool and process development Management of suppliers during tool and process development - Evaluation of tool tests, recommendations for tool corrections and design changesEvaluation of tool tests, recommendations for tool corrections and design changes- FAI / CpK development and evaluationFAI / CpK development and evaluation- New part analysis (form / fit / function)New part analysis (form / fit / function)

Recent Projects / ContributionsRecent Projects / Contributions

Saw Stop, Tualatin, Oregon:Saw Stop, Tualatin, Oregon:

Engaged by Saw Stop to cost-reduce the primary components in Engaged by Saw Stop to cost-reduce the primary components in their “Saw-Stop” safety module and saw-blade Arbor used in their “Saw-Stop” safety module and saw-blade Arbor used in wood processing equipment.wood processing equipment.

- Evaluated costs, manufacturing locations, materials, processes Evaluated costs, manufacturing locations, materials, processes and designs of existing plastic and metal parts to uncover areas and designs of existing plastic and metal parts to uncover areas for possible reduction.for possible reduction.

- Provided a 3-level analysis with part design details, CAD Provided a 3-level analysis with part design details, CAD models, supplier recommendations and new costs to Saw Stop:models, supplier recommendations and new costs to Saw Stop:

1.) Current part designs produced at new manufacturing suppliers.1.) Current part designs produced at new manufacturing suppliers.2.) Subtle design changes to current parts with manufacturing at new 2.) Subtle design changes to current parts with manufacturing at new

suppliers. suppliers. 3.) Complete re-designs with new materials, processes and 3.) Complete re-designs with new materials, processes and

suppliers. suppliers.

Result:Result: Saw Stop is currently implementing combinations of levels # Saw Stop is currently implementing combinations of levels # 1 & # 2 which will yield an overall cost savings of 36% for the 1 & # 2 which will yield an overall cost savings of 36% for the safety module. The remaining parts in the module will undergo safety module. The remaining parts in the module will undergo similar changes after the primary parts and will yield an similar changes after the primary parts and will yield an additional 20% savings. The saw-blade Arbor cost proposal additional 20% savings. The saw-blade Arbor cost proposal resulted in a 64% reduction that is also being implemented.resulted in a 64% reduction that is also being implemented.

- Managed new suppliers during tool, process and sample part Managed new suppliers during tool, process and sample part development in China. Monitored technical communication for development in China. Monitored technical communication for Saw Stop after the transition to new suppliers.Saw Stop after the transition to new suppliers.


Ostendo Technologies, Carlsbad, CaliforniaOstendo Technologies, Carlsbad, California

Acquired by Ostendo as an extension of their mechanical design team Acquired by Ostendo as an extension of their mechanical design team for concurrent development of a large, leading-edge curved for concurrent development of a large, leading-edge curved monitor for the gaming market. The goals were in keeping costs monitor for the gaming market. The goals were in keeping costs and schedule to a minimum while maintaining design intent.and schedule to a minimum while maintaining design intent.

- Daily dialog with the Carlsbad design team and remote industrial Daily dialog with the Carlsbad design team and remote industrial designer to review and update design files, direct part designs for designer to review and update design files, direct part designs for manufacturability, assembly, tooling and process best practices manufacturability, assembly, tooling and process best practices and, material selections. Provided alternate part designs, and, material selections. Provided alternate part designs, features, material and process selections and specifications.features, material and process selections and specifications.

- Parallel to directing part designs within each category, suppliers Parallel to directing part designs within each category, suppliers were recommended for die-casting, plastic injection molding, were recommended for die-casting, plastic injection molding, compression molding, extrusion, thixomolding, as well as large compression molding, extrusion, thixomolding, as well as large and small stamped parts. On-site assessments were completed in and small stamped parts. On-site assessments were completed in Asia for all new sources prior to recommendations being finalized.Asia for all new sources prior to recommendations being finalized.

- Collaborated directly with all suppliers as a technical liaison to Collaborated directly with all suppliers as a technical liaison to initiate the relationship, direct the RFQ process, kick-off tooling, initiate the relationship, direct the RFQ process, kick-off tooling, request sample parts and optimize manufacturing processes.request sample parts and optimize manufacturing processes.

- Completed tool design reviews, fill analysis and final tool design-Completed tool design reviews, fill analysis and final tool design-approval. Evaluated sample parts and inspection reports on-site approval. Evaluated sample parts and inspection reports on-site at suppliers. Recommended solutions to problems found.at suppliers. Recommended solutions to problems found.

Result:Result: Product cost targets, component quality and tool development Product cost targets, component quality and tool development schedules were met or exceeded. In most cases, Ostendo did schedules were met or exceeded. In most cases, Ostendo did not have manufacturing sources for these components or an not have manufacturing sources for these components or an internal ability to fully design for tool and process needs. Created internal ability to fully design for tool and process needs. Created additional time for part designers to complete other design and additional time for part designers to complete other design and validation tasks (critical to a young and lean-staffed start-up)validation tasks (critical to a young and lean-staffed start-up)


Light Speed Aviation, Lake Oswego, OregonLight Speed Aviation, Lake Oswego, Oregon

Engaged By Light Speed Aviation in several capacities: brain-storming Engaged By Light Speed Aviation in several capacities: brain-storming of new product concepts, cost reduction / quality improvement of of new product concepts, cost reduction / quality improvement of existing products and, development of new high-end audio existing products and, development of new high-end audio products used in the aviation industry.products used in the aviation industry.

- Evaluated field-returns of existing components to assess failure Evaluated field-returns of existing components to assess failure symptoms, determine root-cause and to define solutions. symptoms, determine root-cause and to define solutions. Solutions were implemented and measured to assure root-cause Solutions were implemented and measured to assure root-cause had been addressed.had been addressed.

- Conducted on-site assessments of Chinese manufacturing Conducted on-site assessments of Chinese manufacturing sources to assess capabilities and capacities as well as to gather sources to assess capabilities and capacities as well as to gather details toward resolution of problem areas.details toward resolution of problem areas.

- Provided real-time design feedback and direction during Provided real-time design feedback and direction during development of a new model earphone and battery module to development of a new model earphone and battery module to assure cost, quality and schedule were met. This included plastic assure cost, quality and schedule were met. This included plastic material and process recommendations, definition of secondary material and process recommendations, definition of secondary processes, alternate part designs, design direction of internal processes, alternate part designs, design direction of internal designer for selected processes and, tooling development / designer for selected processes and, tooling development / management.management.

- Recommended suppliers to improve cost and quality issues. Recommended suppliers to improve cost and quality issues. Collaborated with suppliers and Light Speed with regard to tool Collaborated with suppliers and Light Speed with regard to tool designs, part consistency and processing issues.designs, part consistency and processing issues.

- ResultsResults: Existing production part quality issues were eliminated. : Existing production part quality issues were eliminated. New concepts offered were implemented into part designs and New concepts offered were implemented into part designs and were released with no schedule delays due to incomplete designs were released with no schedule delays due to incomplete designs or non-producible features. Part quality surpassed prior designs or non-producible features. Part quality surpassed prior designs (very important to this high-end-market supplier).(very important to this high-end-market supplier).

Recent Projects / ContributionsRecent Projects / ContributionsSure Power Industries, Tualatin, Oregon Sure Power Industries, Tualatin, Oregon (Cooper-Bussman)(Cooper-Bussman)

Acquired by Sure Power to monitor mechanical development of Acquired by Sure Power to monitor mechanical development of their numerous power management products aimed at the their numerous power management products aimed at the RV, Military, and fleet-vehicle markets as well as reviewing RV, Military, and fleet-vehicle markets as well as reviewing product quality and tool-life issues with existing product.product quality and tool-life issues with existing product.

- Evaluated field-related returns of existing product to assess Evaluated field-related returns of existing product to assess failure mode and root-cause. Recommended solutions and failure mode and root-cause. Recommended solutions and measured results so assure resolution. In some cases, on-measured results so assure resolution. In some cases, on-site visits at component suppliers were required to assess tool site visits at component suppliers were required to assess tool condition, maintenance records and, process methods.condition, maintenance records and, process methods.

- Assessed current Chinese die-casting sources on-site to Assessed current Chinese die-casting sources on-site to review schedule duration and process capabilities. Dissected review schedule duration and process capabilities. Dissected schedule tasks and offered suggestions on schedule schedule tasks and offered suggestions on schedule improvement to the customer and assembly supplier.improvement to the customer and assembly supplier.

- Provided concurrent design feedback and direction during Provided concurrent design feedback and direction during component development (die-cast, injection-molded plastic & component development (die-cast, injection-molded plastic & stamped metal parts) to assure cost and schedule were met. stamped metal parts) to assure cost and schedule were met. Contributions were in material and process recommendations, Contributions were in material and process recommendations, alternate designs, secondary processes, process capabilities, alternate designs, secondary processes, process capabilities, tooling direction and management.tooling direction and management.

- Educated internal procurement and development teams on Educated internal procurement and development teams on Asian business practices, non-domestic part and tool Asian business practices, non-domestic part and tool development and best practices for communication and development and best practices for communication and business protocol.business protocol.

- ResultsResults: Current product quality and tool issues were : Current product quality and tool issues were corrected. New product designs were optimized to allow for corrected. New product designs were optimized to allow for reduced part and tool cost, schedule reduction and improved reduced part and tool cost, schedule reduction and improved quality over earlier designs. quality over earlier designs.

Select Projects / ContributionsSelect Projects / Contributions

InFocus Corporation, Wilsonville, OregonInFocus Corporation, Wilsonville, Oregon

(Personal employer for 12 years prior to forming Technical (Personal employer for 12 years prior to forming Technical Dimensions)Dimensions)

1.)1.) LP-120 Ultra-Portable Projector: LP-120 Ultra-Portable Projector:

- Directed 4 internal part designers (and 1 remote Directed 4 internal part designers (and 1 remote designer) in “Design For Manufacturability” with plastics, designer) in “Design For Manufacturability” with plastics, thixomolded magnesium and sheet metal stamping thixomolded magnesium and sheet metal stamping (concurrent design and development). This included (concurrent design and development). This included material and process selection, management of all material and process selection, management of all mechanical part suppliers and all tool and process mechanical part suppliers and all tool and process development (38 tools). Also acted in a “hands-on” development (38 tools). Also acted in a “hands-on” design capacity with several sub-systems of the design capacity with several sub-systems of the product. product.

ResultResult: 4 personal (sole-designer) mechanical design : 4 personal (sole-designer) mechanical design patents were granted. No schedule slippages were patents were granted. No schedule slippages were seen due to incorrect part designs or improper material seen due to incorrect part designs or improper material selections. Developed capabilities with 2 suppliers that selections. Developed capabilities with 2 suppliers that previously were not available. Cost and quality targets previously were not available. Cost and quality targets were surpassed for both tooling and components. were surpassed for both tooling and components. Reduced the overall development schedule by 20%.Reduced the overall development schedule by 20%.

Note: This was an multiple award-winning, leading-edge Note: This was an multiple award-winning, leading-edge product that pushed the small size envelope much product that pushed the small size envelope much further than previous efforts.further than previous efforts.

Select Projects / ContributionsSelect Projects / Contributions

InFocus Corporation, Wilsonville, OregonInFocus Corporation, Wilsonville, Oregon

2.)2.) “777” Home Theatre Projector: “777” Home Theatre Projector:

This product was designed by an external partner in Asia who This product was designed by an external partner in Asia who ultimately produced tooling, production parts and the final ultimately produced tooling, production parts and the final assembly. InFocus directed the product architecture and (via assembly. InFocus directed the product architecture and (via my position) monitored the part design and tool development my position) monitored the part design and tool development processes. InFocus was the owner / recipient of all processes. InFocus was the owner / recipient of all production tooling.production tooling.

Result:Result: $700K reduction in tool costs$700K reduction in tool costs from those from those proposed by the partner development company. This was a proposed by the partner development company. This was a direct result of reviewing all final part designs and making cost direct result of reviewing all final part designs and making cost decisions according to part complexity, material, part size decisions according to part complexity, material, part size and, tool type and design. The sum total of these figures was and, tool type and design. The sum total of these figures was compared to those from the partner ($700K delta) and used compared to those from the partner ($700K delta) and used as a means for the $700K cost reduction.as a means for the $700K cost reduction.

3.) 3.) Transfer of projector manufacturing from Malaysia to China:Transfer of projector manufacturing from Malaysia to China:

Directed the transfer of over 250 molds, casting dies, stamping Directed the transfer of over 250 molds, casting dies, stamping dies and related processes, fixtures, jigs and gages to new dies and related processes, fixtures, jigs and gages to new sources in China. This included directing existing suppliers, sources in China. This included directing existing suppliers, freight sources, documenting process specifics, tool condition, freight sources, documenting process specifics, tool condition, part status and tool details for transfer into China. After part status and tool details for transfer into China. After arrival, on-site tool tests, FAI and Cpk studies and part arrival, on-site tool tests, FAI and Cpk studies and part analysis were directed at each source to bring production analysis were directed at each source to bring production back on-line as quickly as possible without circumventing part back on-line as quickly as possible without circumventing part and tool quality or production of parts.and tool quality or production of parts.

Technical Dimensions LLC

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