Beckman Dickerson BD

Principal Engineer / Quality Engineering Leadership for Production Optimization

Directed quality and production optimization across three BD medical device lines, achieving a 98% FPY and a 40% productivity boost through CAPA, SPC, and frontline-driven improvement systems.
HOW WE HELPED
  • Served as the Principal Quality Engineer overseeing three production lines of medical devices: PCA, SYR, and LVP.
  • Led a cross-functional Product Focus Team (including Quality, Electrical, Mechanical Engineers, and Production Management) to drive continuous quality and operational improvements.
  • Conducted defect failure investigations on the production floor and implemented corrective and preventive actions (CAPA) to reduce recurring issues.
  • Designed and implemented inspection plans for incoming materials, rework, and final inspections.
  • Developed KPI metrics for all three production lines, targeting a First Pass Yield (FPY) of 95% — successfully exceeded this goal by achieving 98% FPY through defect reduction and process standardization.
  • Implemented Statistical Process Control (SPC) charts to proactively monitor process shifts and maintain product consistency.
  • Strengthened supplier collaboration by leading root cause investigations and corrective actions, significantly reducing PCB board failures and improving Return Material Authorizations (RMAs).
  • Redesigned manufacturing floor layout, reducing unnecessary motion and transportation within the process by 40%, enhancing productivity and flow.
  • Established High-Performance Teams (HPT) to foster proactive employee engagement, involving frontline staff in KPI reviews and promoting a culture of continuous improvement.
  • Recognized and rewarded employee-driven improvement ideas, empowering the workforce to contribute to operational excellence and own implementation outcomes.
  • First Pass Yield Achieved

    98%

    Target FPY

    95%

    Layout Efficiency Gain

    40%

    Production Lines Managed

    3
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