Tech

Fund raising for the leukemia & lymphoma society.

Fifteen years experience leading the scale up of R&D processes for production, eleven years in Ceramic Matrix  and Plastic Matrix Composites and four years in Plastic Conversion and Vacuum Deposition industry.

Experience in cross functional Product Development. 

Masters Degree in Materials Science. 

Track record of successful development and continuous improvement of enabling technologies.

Creative problem solver with multidisciplinary approach.

Desire and adaptability to master new technology.

Experience with Ultra High Vacuum systems and deposition technology.

Extensive knowledge of data analysis, ISO Quality System, and physical characterization methods.

Certified Internal Quality Management System Auditor.

Key competencies?:

Materials Science 
Statistical Process Control
8D
FMEA
Materials Characterization
Design of Experiments
Root Cause Analysis
Process Development
Process Improvement

*Achieved highest annual cost savings ($340,000) of all Operations employees in 2014 by improving machine utilization and identifying raw material CTQs.

*Created process flows for metallized film production for Healthcare and Display markets based on R&D trial process data leading to On-Time Delivery of product and Increased Customer Satisfaction.

* Developed optimized Process Specifications to increase Cpk of window film products.

* Deployed Mini-Gravure, Mayer Rod, and Slot Die coating systems. 

* Led successful window film product launches through stage gate development process. 

* Designed and led product development trials for high performance automotive sunroof safety film. 

* Improved Product Development capabilities by identifying differences between UV cure lamps used on production lines and lamps in R&D. Optimized settings of R&D lamp to match output of production lamps.

* Designed and implemented mitigation actions in response to uncontrollable variation in raw material component resulting in successful production campaigns.

* Led Root Cause investigations of window film defect and implemented Corrective Actions.

* Initiated protocol to screen raw material for contamination prior to production, resulting in product yields at target levels.

* Analyzed SEM/EDX data to determine composition of embedded contaminants.

* Led evaluation of airborne particle counts in production clean rooms and applied findings to improve cleanliness of production conditions.

* Identified LED ultraviolet light source and evaluated potential compatibility with in-house coating technology.

Process Engineer at Saint-Gobain Solar Gard, LLC

* Managed $175,000 program to develop design allowables for a high strength ceramic composite material. Created work flows, managed fabrication of test material, issued RFQs, reviewed vendor quotes, issued and modified Purchase Orders, and analyzed test data and reported material design allowables to customer.

* Identified and mitigated critical chemical reactions affecting life of an Invar tool. Reduced tool turn around time from twenty-four hours to six hours.

* Managed $60,000 program to develop design allowables for a low cost ceramic composite material. Created work flows, managed fabrication of test material, issued RFQs, reviewed vendor quotes, issued and modified Purchase Orders, and analyzed test data and reported material design allowables to customer.

* Managed program to develop laser drilling of blind effusion holes at various angles into ceramic composite. Led development of fugitive tooling material to create blind cooling channels in ceramic composites.

* Developed process to cast insulation material onto exhaust washed ceramic surfaces.

* Optimized casting process of ceramic fibrous insulation resulting in 30% increase in tensile strength.

* Developed successful tape and filament winding processes for wet winding ceramic composites resulting in a 30” diameter combustor liner surviving more than 25,000 hours of continuous use in the field.

* Identified and characterized a glass coating for ceramic parts suitable for temperatures between -40°C and 800°C.

* Developed method to co-process oxide and carbide ceramic parts to achieve unique range of properties.

Senior Engineer - COI Ceramics, Inc., an Affiliate of ATK

Find out detailed information about Carlos Bacalski,  in San Diego, CA

Carlos Bacalski: in San Diego, CA

Carlos Bacalski

Solar Gard

ATK

University of California, San Diego

The Johns Hopkins University