Joe Dunn

About Joe Dunn

Helping advanced and molecular-scale manufacturing teams turn “mystery variation” into stable, high-yield performance—by applying Senior Quality Engineer and Continuous Improvement leadership to processes where precision, defect rates, and throughput really matter.​What I Do (Senior QE / CI Leader) Lead focused optimization events where cross-functional teams shortlist suspect variables, design lean experiment plans (practical DOEs), and quickly separate signal from noise in complex processes—from nano-/molecular assembly to robotics-heavy automated cells.​ Translate hard physics and surface realities (Å-level positioning, passivated surfaces, vacuum/contamination, thermal and vibration effects, motion profiles) into clear test plans and control strategies that scientists, engineers, and operators can actually run and sustain.​ Turn messy, multi-factor systems into a few controllable “knobs” with defined good vs marginal levels, then lock in, document, and standardize the winning conditions across tools, lines, and shifts.​Who I Help Molecular / nano engineering and atomically precise manufacturing startups that need to move from demo-grade to product-grade reliability without a year of random trial and error.​ VP Engineering / Directors overseeing robotics-heavy or high-precision cells who need a Senior Quality / CI partner to improve throughput, precision, and uptime at the same time.​ Operations and quality leaders in “traditional” manufacturing who are serious about real process capability (Cpk, scrap, downtime) and culture change—not just inspection and audits.​How I Work With Teams Define the critical Y (positional accuracy, defect/error rate, or cell throughput) and build a ranked suspect list across mechanics, materials, environment, and methods.​ Create a practical suspect matrix with clear good/marginal ranges, then run fast preliminary and separation experiments to see which factors actually move the Y.​ Set the key inputs to their new correct levels, document centerlined conditions, and support replication so gains don’t evaporate when tools, shifts, or products change.​Impact as a Quality / CI LeaderUsing this structured experimentation and centerlining approach, teams have cut scrap by over 95% on critical lines, eliminated chronic breakdown patterns while training internal staff to prevent recurrences, and raised Cpk from <1.0 to well above 2.5—shifting from firefights to predictable, high-margin performance.

Experience

1. Quality Engineer

   Foxconn E BG Group

   Feb 2022 — Present · Lordstown, OH, US

   Executed laser weld pull test variation reduction plan for performance optimization Tracked down causes of power Pack voltage imbalances; identified causes failures and led controls and corrections Co-created FMEAs with 7 Engineers in highest risk priorities areas Led active data collection to determine issue causes Deployed torq test auto data system Guided and co-created a Suspect Resolution Grid for a key sub-assembly failure Devised supplier control protocol for Design Responsible Engineers Responsible for Motor Quality approvals Completed control plan creations for entire Motor department Expert in active test plans including Variables Search, BobWow, Components Switch, Multivari, Mini-Capability comparisons, 5pc capability analysis

Education

• Eaton University

  Certified Black Belt, Six Sigma

• Iowa State University

  BS, Industrial Engineering

  1990 — 1995

• American Society for Quality

  Certified Manager of Quality / Organizational Excellence, Management