Ryan Kane

• Developed manufacturing and assembly processes for complex electro-mechanical robotic surgical instrumentation. • Provided DFM/DFA guidance and contributed to mechanical design iterations to improve subsystem reliability. • Collaborated with supply chain, vendors, and contract manufacturers to improve manufacturing processes, refine part designs, and reduce COGS, including transitioning components from CNC machining to injection molding/MIM. • Designed assembly fixtures, inspection fixtures, and electrical/mechanical test fixtures for the disposable instrument subsystem. • Created manufacturing documentation including Assembly WIs, Routers, Process Flow Diagrams (PFDs), Manufacturing Validation Plans, PFMEAs, and NCRs. • Worked with Electrical/Software Engineering to develop electrical test fixtures for joint-sensing signal verification during assembly and final end-of-line testing. • Helped design and build an ISO 7 cleanroom assembly line in-house, from concept through operation. Notable NPI Projects: • Improved reliability of polymer cable-driven instruments by increasing cable life from <1 hour to 8+ hours through mechanical redesign, rapid prototyping, process refinement, and collaboratively resolving major inductive sensing issues with EE/SW teams. • Transitioned a novel disposable robotic instrument from an early-stage prototype to a fully traceable ISO 7 cleanroom-built device, including development of the complete assembly process, fixturing, documentation, and EtO sterilization readiness.

• Worked on a two-person prototype manufacturing team in an early-stage medical robotics startup. • Partnered with R&D to improve part manufacturability/machinability, refine GD&T, and iterate mechanical designs. • Provided DFM and drawing review support across all subsystems of the robotic surgical system. • Programmed, set up, and ran Haas 5-axis CNC machines using Mastercam; maintained the company’s prototype fabrication shop. • Designed and fabricated CMM inspection fixtures and developed inspection plans for complex components.

• Sustained CNC machining, SLS additive manufacturing, and clean-room assembly processes for custom orthopedic implants and surgical jigs. • Implemented process improvement projects that increased production efficiency and product quality across machining, SLS, and clean-room workflows. • Conducted process validations and statistical analysis to determine process capability and ensure compliance. • Performed investigations and root-cause analysis of non-conforming materials/products; executed NCMR, CAPA, and ACA actions. • Participated in FDA and BSI audits as a subject matter expert for machining and additive manufacturing processes. • Authored and updated SOPs, Work Instructions, DHR travelers, and process documentation. • Monitored, analyzed, and presented process trend data for machining, SLS additive, and clean-room production cells. • Executed and documented IQ, OQ, and PQ validation activities. • Developed formal training programs for clean-room and machining production personnel. Notable Projects • Updated CAM program parameters for cobalt-chromium and UHMWPE implants, reducing machining cycle time by 25%+ per part and improving surface finish; completed statistical validation of new programs. • Qualified a newly designed three-layer clean-line basket, enabling increased part throughput per batch and improved cleaning process efficiency.

• Designed and developed new cutting tool products for the CNC machining industry based on market research and performance testing. • Supported QA inspection and provided technical guidance on machining applications for customers and sales engineers.

• Maintained plastic injection molds and operated a CNC machines to process medical, military, industrial and specialty electronics products.    • Gained hands-on experience with injection molding process and an introduction to plastic part and injection mold design.

Completed a Design and Manufacturing Engineering Graduate Certificate consisting of the following 5 courses: • Medical Device Design • Plastic Product Design • Engineering Project Management • Quality Engineering • Reliability Engineering