James Roche
Charleville
Summary
Senior NPI Engineer with 20+ years' experience in Manufacturing, holding a BEng in Industrial Engineering, and a Lean Blackbelt from University of Limerick. Key Skills: Project Management - Flawless Project Execution (FPX) certified. Lean Manufacturing - Lean Blackbelt certified from University of Limerick. Process Improvement - Five years' experience leading Global Process Improvement projects. New Product Introduction - Three years' experience working on NPI projects for DePuy Synthes. CAM/CNC - Twenty years' experience in Computer Aided Machining and CNC Machining. Medical Device Manufacture - Twenty years'+ experience in the Design and Manufacture of Medical Device Tooling and Fixturing. Third Wave CAM Optimisation - SME for Third Wave CAM Optimisation software.
Consumer-minded product engineer with several years designing exceptional retail and business offerings. Well-versed in incorporating end-user needs and desires into foundational product elements. Dedicated to developing financially successful products to please existing customers and attract new audiences. Goal-oriented professional with experience in settings. Forward-thinking when reviewing project requirements to determine precise solutions. Composed professional when working under tight schedules and limited budgets to achieve innovative designs meeting and exceeding objectives.
Overview
25
25
years of professional experience
Work History
Senior NPI Engineer - PPD
Depuy Synthes
Ringaskiddy
11.2021 - Current
- Leading CNC machining core team to develop and implement machining and inspection processes for some of DePuy Synthes key NPI projects
- Drafting procedures, work instruction and inspection documents to be used by associates during production
- Installation and validation of CNC Machining Assets
- Working with OEMs for fixture, tooling and machine design and development.
CNC Manufacturing Engineer - CAM Centre / Machining CoE
Depuy Synthes
Ringaskiddy
09.2016 - 11.2021
- Leading CNC development projects, reducing manufacturing costs and improving CNC machining strategies and capabilities across the global orthopaedic network
- Engaging with external CNC application development vendors to improve speed and scale of CNC development and duplication
- Delivering key projects for the Machining VT group ensuring targets are achieved
- Driving continuous process improvements / capacity increases through new technology and equipment introductions
- Design & develop tools, fixtures, gauges and special equipment for manufacturing operations and new product / process introductions in conjunction with toolroom technicians and manufacturing engineers globally
- Identify capital spend and budget requirements for process improvements
- Preparation and maintenance of all relevant manufacturing specifications
- Preparation and project management of all projects including supporting documentation as required
- Focus on reduction of unit cost of production ensuring project scope and targets are correctly specified and achieved through the project
- Supporting ongoing Safety Incident corrective actions and ERGO team initiatives/actions
- NPI - developing robust machining processes for new products.
Senior Offline Programmer/Continuous Improvement Lead/Team Lead
Shannon Precision Engineering
Shannon
07.2010 - 08.2016
- Project managing continuous improvement projects
- CNC programming using Mastercam X6 and OneCnc programming software
- Planning and organising programs and resources to meet daily and weekly schedules
- Training apprentices and team members in all aspects of manufacturing, machining, measuring components etc
- Completing daily production reports and setting shift targets
- Ensuring a high standard of housekeeping and maintaining a safe work environment
- Completing scrap reports
- Liaising with the QC department to perform APQP (Advanced Product Quality Planning) and part checking
- Process improvements
- Lean implementation
- Ensuring waste management procedures are complied with.
Toolmaker/ CNC Programmer
Munster Tool and Die ltd
Little island
03.1999 - 01.2010
- Design and manufacture of special purpose jigs, fixtures, and machine components to engineering drawings utilising all in workshop machinery and resources
- Material sourcing and tooling purchases
- Liaising with customers when required on matters relating to manufacture of tooling components
- Final inspection of finished goods and completion of inspection reports
- Toolroom machine routine maintenance
- On site visits to customers and sub-contract work to customer sites when required.
Education
Batchelor of Engineering in Industrial Engineering -
Griffith College Limerick
02.2020
Post Graduate Diploma in Quality Management / Lean Systems -
University of Limerick
12.2015
Senior Trade Certificate - Toolmaker -
Sligo Institute of Technology
12.2003
Junior Trade Certificate - Toolmaker -
Sligo Institute of Technology
12.2002
City and Guilds Certificate in Machine Tool Operating -
FAS Training Centre Raheen
03.1999
Skills
- Project Management
- Flawless Project Execution (FPX) certified
- Lean Manufacturing
- Lean Blackbelt certified from University of Limerick
- Process Improvement
- Five years' experience leading Global Process Improvement projects
- New Product Introduction
- Three years' experience working on NPI projects for DePuy Synthes
- CAM/CNC
- Twenty years' experience in Computer Aided Machining and CNC Machining
- Medical Device Manufacture
- Twenty years' experience in the Design and Manufacture of Medical Device Tooling and Fixturing
- Third Wave CAM Optimisation
- SME for Third Wave CAM Optimisation software
- Process Engineering
- Cost-reduction strategies
- Functional Testing
- Cross-Functional Teamwork
- Prototype Development
- Manufacturing process understanding
- Timeline Management
- Technical solution development
- Continuous Improvement
- Lean manufacturing principles
Accomplishments
- Lead Global Cost Improvement Projects which generated over €4.5M savings for the organisation - 2016 > 2019
- Implemented CAM Optimization Software which has the potential to reduce Machining cycle on all processes globally by up to 20% - 2017
- Nominated for a Lever Award for Innovation and Collaboration - October 2019
- Awarded a Platinum J&J Encore Award for Leadership - January 2019
- Nominated for a Lever Award for Innovation and Collaboration - November 2018
- Raised over €100,000 for local charities from 2017 > 2019
- Lead a cross functional team to design and implement fixturing for the Attune Revision Cones NPI, which improved CNC Machining fixturing and enabled full batch machining (12 parts) as opposed to single part machining - February 2020 > June 2020.
- Executed process verification on the Attune Revision Cones NPI - March 2023.
- Successfully delivered a validated machining process for the Attune Revision Cones - 3D printed component - February 2020 > April 2023.
References
- Andrew Fanning, Quality Control Manager, Shannon Precision Engineering, 061-474494
- Gerry Kelly, Production Supervisor, Shannon Precision Engineering, 087-9861853
- Sean Hayes, Managing Director, Munster Tool & Die Ltd, 021-4524640
- Benjie Tabuno, Lead Design Engineer, Munster Tool & Die Ltd, 087-7901104
Hobbies and Interests
- Muay Thai
- Mountain Biking
- Road cycling
- Reading
- Cooking
- Fundraising
Timeline
Senior NPI Engineer - PPD
Depuy Synthes
11.2021 - Current
CNC Manufacturing Engineer - CAM Centre / Machining CoE
Depuy Synthes
09.2016 - 11.2021
Senior Offline Programmer/Continuous Improvement Lead/Team Lead
Shannon Precision Engineering
07.2010 - 08.2016
Toolmaker/ CNC Programmer
Munster Tool and Die ltd
03.1999 - 01.2010
Batchelor of Engineering in Industrial Engineering -
Griffith College Limerick
Post Graduate Diploma in Quality Management / Lean Systems -
University of Limerick
Senior Trade Certificate - Toolmaker -
Sligo Institute of Technology
Junior Trade Certificate - Toolmaker -
Sligo Institute of Technology
City and Guilds Certificate in Machine Tool Operating -
FAS Training Centre Raheen
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