I have been involved in several projects that failed to perform to expectations, or turned out to be economically disastrous for my employers.
In some of those cases, I 'threw a red flag' well before the peanut butter hit the fan.
... and was roundly condemned by Marketing types and MBAs for 'having a bad attitude' or 'not being a team player',
despite engineering analysis and reasoning based on fact or some semblance thereof.
I can't say that speaking up was good for my career.
In other cases, I was able to do post-mortem analysis that revealed hidden causes of problems, and sometimes led to a solution. I was able to use some of those small successes as 'mini-stories' in my resume. I will quote one such mini-story below:
{
* Solved an injection molding shrinkage/ scratching problem by calculating that a stainless steel sleeve insert would be plastically deformed by 9000 psi molding pressure to .0012" larger than the mold pin, regardless of the sleeve’s initial size. Then the molder admitted grinding the pin undersize to ease sleeve placement.
}
To expand a bit on the story, we were making diluters which included a ~2.25" dia Teflon piston riding in a precision lapped, ~.030" wall stainless steel sleeve, which was in turn insert molded in a PVC plastic cylinder assembly. We supplied the finished sleeves to a molder, who was supposed to slip them over a mold pin about .0002" smaller than the sleeve. The machine was a suboptimal design in a lot of ways, but it had been in production for decades. All of a sudden we got complaints about leaks between the piston and cylinder, which were traced to axial scratches in the cylinder. Said scratches were not present in the parts we supplied to the molder. Close examination of a few assemblies and careful analysis of the molding conditions suggested that the axial marks in the finished molded-in sleeves were not scratches, but actually tight folds that could have occurred if the mold pin was too small. A few telephone calls revealed that the molder had ground the pin undersize by .005" in order to make placement of the sleeves easier, and faster. Replacing the mold pin made the problem go away.
Mini-stories like that, focused very tightly on one problem and a solution, can enhance a resume without identifying the product, and are independent of the product's fate or reputation.
Mike Halloran
Pembroke Pines, FL, USA