FEA Consultant Henry Magallanes
Henry is an seasoned manufacturing professional with extensive experience in FEA Consulting.
Henry is a seasoned manufacturing professional with extensive experience in plastic injection mold design. He held positions of progressive responsibility holding all positions from Mold Maker to General Manager of a mold shop. His focus and passion for many years was complex action molds. He has designed and built class 101 medical molds for lights out clean room molding as well as multiple cam action, auto-unscrewing, gas assist, RIM, and Low-Pressure molds. Henry has a proven track record of updating technology and processes to improve efficiency and increase profitability. Henry has extensive knowledge in all aspects of many different types of manufacturing including progressive stamping dies, sheet metal fabrication, molding, mold manufacturing, Plant and Production Management. This includes Product Design and Development, DFM and Tooling Design, Process Development, Automation, and Lean Manufacturing implementation.
RECENT ACCOMPLISHMENTS
2024 Andronaco Industries
Led a team of R&D engineers to redesign a line of injection molded natural gas valves
2021 Micro Technologies
In one year, output increased 418% to 46 new tooling projects
2019 Rain Bird Corporation
2016 Nordson Medical
Successfully managed a tooling transfer of an entire product line
PROFESSIONAL EXPERIENCE
March 2023 – January 2025
Andronaco Industries,
Principal Engineer - Molding Transformation
Grand Rapids, MI
Contract position to upgrade the molding technology of a multi-plant operation
October 2020 – February 2023
Micro Technologies
Principal Engineer - Custom Manufacturing Orders
Pompano Beach, FL
Director and SME for the Tooling Department and Process Engineering
January 2019 – May 2020
Rain Bird, Inc.
Senior Tooling Engineer
Tucson, AZ
Responsible for all tooling for the RVAN product line, gear molds and four case molds for outdoor control units
October 2014 – January 2019
Nordson Medical
Senior Tooling Engineer
Loveland, CO
Design and manage the builds of complex injection molds for “Best in Class” lights out medical molder
May 2010 – May 2014
KASO Plastics
Plant/Production Manager
Vancouver, WA
Hired as a Tooling Engineer and promoted to Plant Manager in May 2011. Responsible for all production and maintenance activity within a 50K square foot facility. P&L responsibilities for production and maintenance departments.
January 2009 – April 2010
O’Ryan Industries
Director of Manufacturing
Vancouver, WA
Contracted to develop Contract Manufacturing Division to fill unused capacity of existing Injection Molding equipment. This included molding, machining and assembly work and integrating an MRP system within the current organizational structure. Worked with the entire management team to change the culture from OEM to a customer focused Contract Manufacturer. Managing director for all Molding, Machining, Mold Making, Quality Control, and Contract Assembly operations.
May 2005 – January 2009
Magco, Inc.
President
Vancouver, WA
Owned and operated a custom mold making facility. Concentrating on the design and manufacture of high production plastic injection molds, associated automation, and second operation tooling. Helped customers solve their tooling issues through applying innovative DFM solutions. Shipped many turnkey solutions for molding, automation, and assembly.
August 1990 – May 2005
Cascade Mold and Die
Mold Maker to General Manager
Portland, OR
Built molds and managed projects for many years. Held various positions within the organization and finally promoted to General Manager. Gained experience in building all types of injection molds. Studied and utilized Kaizen and Lean methodologies to increase efficiency which resulted in an increase of profit by 32% over 2 years Instrumental in many R&D projects as a Mold Designer/Maker for large customers in the medical and consumer electronics industries. Also, built the first Gas Assist Mold ever made in Oregon for a global electronic testing manufacturer.
EDUCATION
2024 Andronaco Industries
Led a team of R&D engineers to redesign a line of injection molded natural gas valves
- Reduced material costs by 40%
- Reduced overall manufacturing costs by 80%
2021 Micro Technologies
In one year, output increased 418% to 46 new tooling projects
- Decreased the lead-time by 30%
- Decreased the mold grooming time by 20%
2019 Rain Bird Corporation
- Submitted a tooling optimization plan that increased efficiency by 50% my assigned product line, my duties were then expanded to six lines
2016 Nordson Medical
Successfully managed a tooling transfer of an entire product line
- Consolidated tooling to maximize efficiency and decommissioned worn our molds
- Came in $400k (40%) under budget with the ability to easily expand product offering
PROFESSIONAL EXPERIENCE
March 2023 – January 2025
Andronaco Industries,
Principal Engineer - Molding Transformation
Grand Rapids, MI
Contract position to upgrade the molding technology of a multi-plant operation
- Led initiatives in Injection Molding Machine upgrades
- Design for Manufacturing for all molding operations in four plants
- Injection Molding, Compression Molding, Isostatic Molding, Resin Transfer Molding, Composite Thermoforming, Powder Compaction, Ram Extrusion, and PFA Intrusion Molding
- ROI analysis for multiple Capitol Expense projects to increase production rates by an average of 30%
- Lead a team of R&D Engineers to redesign a line of Injection Molded Natural Gas Valves.
- Reduced material costs by 40%
- Reduced overall manufacturing costs by 80%
- Implemented Process Development and Process Control Systems of multiple molding processes
- Enhanced Quality system by integration of 3D scanning. Taught staff in its usage and benefits
- Launched a comprehensive training program for Scientific Molding using Paulson Training
October 2020 – February 2023
Micro Technologies
Principal Engineer - Custom Manufacturing Orders
Pompano Beach, FL
Director and SME for the Tooling Department and Process Engineering
- Both Department Managers reported to me
- Separated and restructured the Tooling Department into 2 divisions
- In one year, the tool building output increased by 418%
- Optimized the process development time to minimize regression loops
- Introduced SigmaSoft simulation software and embedded it into the NPI process thru AI Based Digital twinning.
- Shop floor optimized through the Theory of Constraints and Lean Methodologies using Managers and Team leads
January 2019 – May 2020
Rain Bird, Inc.
Senior Tooling Engineer
Tucson, AZ
Responsible for all tooling for the RVAN product line, gear molds and four case molds for outdoor control units
- Generated financial justification documents and presented to Senior Management for many new projects
- Managed the mold builds for 15 projects
- Assigned to lead an internal CAPA that resulted in a new SOP to control the disposition of Engineering Samples
- Developed Cost/Capacity Analysis for a product line consolidation
- Provide DFM, Mold Design, Mold Process Optimization and Lean Manufacturing assistance as needed.
October 2014 – January 2019
Nordson Medical
Senior Tooling Engineer
Loveland, CO
Design and manage the builds of complex injection molds for “Best in Class” lights out medical molder
- Designed and launched a tooling program for a BioPharm product that was previously considered un-moldable.
- Managed overseas vendors for a successful launch of a Class 8 Clean Room manufacturing facility
- Successfully managed a tooling transfer of an entire product line. Molds were well built but badly maintained. Had all molds refurbished and updated to run in a lights out environment. Consolidated tooling to maximize efficiency and decommissioned worn out molds. Came in $400k under budget through these changes. With the ability to expand product offering easily
- Developed extensive vendor control documentation system for the latter that was implemented as a SOP
- Provided DFM consulting services for sister companies within the corporation.
- Held SolidWorks and Moldflow classes for junior staff
- Introduced and managed an Apprenticeship Program through CareerWise Colorado
May 2010 – May 2014
KASO Plastics
Plant/Production Manager
Vancouver, WA
Hired as a Tooling Engineer and promoted to Plant Manager in May 2011. Responsible for all production and maintenance activity within a 50K square foot facility. P&L responsibilities for production and maintenance departments.
- Increased profitability by 40% in the first year and held going forward.
- Utilized Lean Manufacturing initiatives, in some cases, as much as tripling throughput while reducing labor per part.
- Production employees achieved the highest quarterly performance bonus ever recorded based on quality and departmental performance
- Launched several employee engagement programs to help to transform the existing workplace to one with a more positive culture.
- Lead the team that created KASO University that provided training for employee advancement.
- Recognized by the CEO as achieving the highest quarterly profit margin in the history of the company.
January 2009 – April 2010
O’Ryan Industries
Director of Manufacturing
Vancouver, WA
Contracted to develop Contract Manufacturing Division to fill unused capacity of existing Injection Molding equipment. This included molding, machining and assembly work and integrating an MRP system within the current organizational structure. Worked with the entire management team to change the culture from OEM to a customer focused Contract Manufacturer. Managing director for all Molding, Machining, Mold Making, Quality Control, and Contract Assembly operations.
May 2005 – January 2009
Magco, Inc.
President
Vancouver, WA
Owned and operated a custom mold making facility. Concentrating on the design and manufacture of high production plastic injection molds, associated automation, and second operation tooling. Helped customers solve their tooling issues through applying innovative DFM solutions. Shipped many turnkey solutions for molding, automation, and assembly.
August 1990 – May 2005
Cascade Mold and Die
Mold Maker to General Manager
Portland, OR
Built molds and managed projects for many years. Held various positions within the organization and finally promoted to General Manager. Gained experience in building all types of injection molds. Studied and utilized Kaizen and Lean methodologies to increase efficiency which resulted in an increase of profit by 32% over 2 years Instrumental in many R&D projects as a Mold Designer/Maker for large customers in the medical and consumer electronics industries. Also, built the first Gas Assist Mold ever made in Oregon for a global electronic testing manufacturer.
EDUCATION
- HS Diploma
- Tool and Die Apprenticeship
- Mold Maker Apprenticeship
- Lean Manufacturing Academy
- PMP Training
- Routsis Scientific Molding
- Paulson Scientific Molding
