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Consulting Partners

Chris Tsai Boothroyd Dewhurst, Inc.

Chris Tsai is the Director of DFMA Implementation Services at Boothroyd Dewhurst. He has over 25 years of engineering, change management, and leadership experience with the Eastman Kodak Company and the Rochester Institute of Technology (RIT). Most of that time was spent in the equipment product design and manufacturing portion of Kodak’s operations (i.e. digital cameras, scanners, printers, medical imaging devices, etc.). He has held positions in product & tooling design engineering, manufacturing engineering, project management, quality management, and globalization. Early in his career, he established himself as a corporate subject matter expert in Value Analysis/Value Engineering (VA/VE) and Design for Manufacture & Assembly (DFMA) and later expanded that expertise to Lean Six Sigma being certified as a Black Belt and becoming a corporate Lean Six Sigma instructor and mentor. He has developed and delivered corporate training and certification around the world and is a SAVE International certified Associate Value Specialist (AVS).

As Quality & Process Improvement Manager in Kodak’s Health Imaging Group, he led the establishment of a new Supplier Quality function driving an order of magnitude reduction in defects and scrap material costs in less than three years. As Globalization Manager, he led the Lean Six Sigma Manufacturing initiatives transforming Kodak Health Imaging’s Minnesota and Shanghai, China hardware manufacturing operations. As a DFMA sensei, he has helped teams identify over $100M in potential cost savings and avoidance.

Chris has a Bachelor’s Degree in Mechanical Engineering from Purdue University and a Master’s Degree in Manufacturing Engineering from the Rochester Institute of Technology.

Contact Chris at: ctsai@dfma.com or 1-585-348-8115

Areas of Expertise
  • DMAIC Lean Six Sigma
  • Design for Six Sigma (DFSS)
  • Root Cause Analysis / Analytical Problem Solving / CAPA
  • Design for Manufacture & Assembly (DFMA)
  • Value Analysis / Value Engineering (VA/VE)
  • Team Leadership and Change Management Skills
  • Operations Management incorporating Lean Manufacturing and Six Sigma methodologies
  • Supplier Quality Management
Robert Williams Creative Design Solutions
Founder & President of Creative Design Solutions, a comprehensive product development consulting firm. Bob was with HP and Agilent Technologies for 27 years and has been a Boothroyd Dewhurst Workshop Instructor for over 18 years where he has trained over 2,500 engineers in DFMA and Creative Design. His 21 years of manufacturing experience includes extensive instrumentation product development and PCA/SMT process engineering and 6 years of R&D Design experience in both high volume products and specials. Bob is the published author in DFA for 2 university textbooks and is a past president of the Rocky Mountain Council for Competitive Products.
Areas of Expertise
  • Able to lead & inspire groups to achieve breakthrough results. 18 years experience in training over 2,500 engineers in DFMA and Creative Design
  • ‘Hands on’ Manufacturing Experience. 21 years of personal manufacturing experience including extensive instrumentation product development, as well as PCA/SMT process engineering
  • ‘Hands on’ R&D Experience. 6 years R&D design experience in both high volume products and specials
Matt Miles VAVE Consulting Services
Matt Miles

Matt Miles is a mechanical engineer with over 17 years of product development experience. He has been practicing DFMA, utilizing Boothroyd Dewhurst’s software, since 2006, during which time he has led the implementation of DFMA at two separate companies. He has held positions as a research & development engineer, value engineer, supplier quality engineer, continuous improvement leader, and value engineering manager.

In his engineering roles, he has participated on teams and been the technical lead for new product development launches and cost reduction projects that have resulted in millions of annualized savings. As a value engineering manager, Matt led the corporate DFMA and Value Engineering initiative across multiple companies in areas such as new product development, product cost analysis, competitive benchmarking, and DFM cost analysis for the supply chain. In addition, he facilitates cross-functional product design reviews and implementation workshops on the DFMA/VAVE tool sets. He has helped integrate these tools into the product development process and company cultures that have resulted in identifying millions in potential cost savings and avoidance, implemented cost savings, and patented product designs.

Matt has been awarded four patents, presented multiple times at Boothroyd Dewhurst’s annual DFMA Forum, and was awarded the Boothroyd Dewhurst supporter of the year award in 2009. He holds a Bachelor’s Degree in Mechanical Engineering Technology from the Rochester Institute of Technology and is a SAVE International certified Associate Value Specialist (AVS).

Areas of Expertise
  • Design for Manufacture & Assembly (DFMA)
  • Value Analysis / Value Engineering (VA/VE)
  • Function Analysis/FAST Diagrams
  • Failure Mode and Effects Analysis (FMEA)
  • Supplier Quality & Development
  • Competitive Benchmarking
  • DFMA integration into the Product Development Process
  • Incorporating DFM cost estimate analysis for Supply Chain purchased price validation
  • Bill of Material Analysis (Pareto chart creation) for identifying areas of opportunity for cost reduction

Software Partners

Convergence Data Services  

Convergence Data Services provides component and supplier management software solutions to the discrete manufacturing industry.  Convergence offers a solution which enables the extension of DFMA cost modeling to the enterprise for increased accuracy, efficiency and effectiveness.  This integrated toolset manages and validates DFMA inputs against company standards and rules and then publishes the models, outputs and other related files to a centralized database for easy access.  Automated refresh capabilities are provided which allow for the automated update of cost analyses against the most up-to-date cost inputs (i.e. material, machine and operation libraries).  Convergence also provides an easy to use search, query and reporting tool which provides cost rollups and competitive cost comparisons.

For more information visit the company’s Web site (www.convergencedata.com) or call 1-203-364-8600.


SOLIDWORKS Corporation, a Dassault Systèmes S.A. (Nasdaq: DASTY, Euronext Paris: #13065, DSY.PA) company, develops and markets mechanical design software solutions. Founded in 1993, SOLIDWORKS’ mission is to unleash the power of 3D for everyone in product development. Only SOLIDWORKS is 100% focused on product design, providing software and services that help manufacturers get new products to market faster. Innovative, yet proven, SOLIDWORKS software is the standard in 3D. In seven years of delivering product, SOLIDWORKS has shipped over 250,000 total seats of software worldwide. SOLIDWORKS has offices around the globe and sells, distributes, and supports its products through a worldwide network of resellers. For the latest news, information, or a live online demonstration, visit the company’s Web site (www.solidworks.com) or call 1-800-693-9000 (outside of North America, call +1-978-371-5000).

Solid Concepts  

SolidView/Pro is a low-cost, easy to use, program for viewing and measuring a variety of 3D CAD data formats. With the SolidView family of products, anyone with a Windows PC can view, measure, and mark up CAD data. Instead of working with confusing paper drawings, you can now have a real-time shaded view of your CAD designs, without the need for expensive CAD hardware or software, and without extensive training.

SolidView/Pro is from Solid Concepts Inc., a privately held corporation headquarted in Valencia, California. Additional information on SolidView and Solid Concepts can be obtained from www.solidview.com. SolidView is a registered trademark of Solid Concepts Inc.


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