Wissam Esmail

Process Engineer with 4+ years of experience improving manufacturing workflows, building custom automation tools, and designing mechanical fixtures that solve real production problems. Comfortable working between the production floor and engineering office. Proficient in SolidWorks, AutoCAD, and Lean Six Sigma methods. Interested in solving mechanical engineering challenges through thoughtful design, practical problem-solving, and continuous improvement.

Automation Engineer - Metrohm - Plainsboro, NJ

(2023-11 - 2025-12)

• Designed and documented mechanical fixtures in SolidWorks, including a Volume Bragg Grating (VBG) laser alignment fixture, improving component alignment precision through automation.
• Directed the implementation and preliminary testing of a crucial PCB upgrade in collaboration with Swiss headquarters, which boosted the product yield from 50% to 95%, thereby enhancing the sensor performance and reliability of spectrometer systems.
• Developed a Python-based system to collect and analyze spectrometer testing data, converting raw data into a structured SQL database, enabling real-time process monitoring and optimization.
• Implemented a novel "Base BOM" structure tailored for highly configurable OEM products, optimizing the accuracy and adaptability of the Bill of Materials.
• Spearheaded the prototype development, production documentation, and transition of new products from design to production, ensuring seamless integration into existing manufacturing processes.

Manufacturing Engineer - Metrohm - Plainsboro, NJ

(2023-01 - 2023-11)

• Authored, revised, and maintained critical documentation including Bills of Materials (BOMs), Standard Operating Procedures (SOPs), and work instructions, ensuring all production activities adhered to the highest standards of accuracy and regulatory compliance.
• Orchestrated training programs for field service engineers on the maintenance and repair of advanced spectrometer systems, enhancing operational proficiency and customer service standards.
• Innovated and implemented a novel quick–release clamp solution at the sensor inspection station, which eradicated potential damage risks and increased operational efficiency by 90%.
• Fostered a collaborative culture by training engineers and technicians on best practices and process optimizations, thereby enhancing overall production quality and efficiency.
• Engaged in active collaboration with the Swiss headquarters, providing essential feedback and implementing improvements in product design and functionality, directly impacting product quality and customer satisfaction.

Foundry Engineer - Dixon Valve - Dayton, NJ

(2021-05 - 2022-12)

• Managed day-to-day operations and scheduling of two high–volume molding lines (British Molding Machine and Hunter Molding Machine), consistently meeting production targets through effective planning and process optimization.
• Supervised the core room operations, leading a team of five in the production of cores for sand mold casting, a critical component for maintaining precision and efficiency in the manufacturing process.
• Controlled inventory and procurement for 15 different metals ensuring resource availability aligned with production needs.
• Enhanced customer relations by proactively communicating order statuses and updates, ensuring commitments were met and fostering high levels of customer satisfaction and trust.

Machine Operator - Hickory Industries - North Bergen, NJ

(2017-10 - 2020-05)

• Operated CNC punch press, lathe, and vertical mill, programming G-code to produce precision components, enhancing hands-on manufacturing skills relevant to casting equipment.

Bachelor of Science - Mechanical Engineering Technology; Minor: in Manufacturing Engineering Technology - New Jersey Institute of Technology (NJIT) | Newark, NJ