Alexandru Dinca

Senior Mechanical Engineer and R&D Management Consultant . New Product development from concept to Production  20+ years of experience delivering real, production-ready products for real-world applications across different industries including industrial connectors, consumer electronics, biometric access control, technical LED lighting, electro-analytical measurement devices, HVAC, and industrial refrigeration  Prevent late design changes by identifying technical and manufacturing risks in the concept phase, using pre-feasibility analysis, VOC translation into engineering requirements, and DFMA analysis  Efficient progression from concept through prototype validation, design freeze ,tooling readiness, and serial production Diploma  Industrial Engineer , Polytehnic Univ of Porto , Portugal Diploma  Master in Manufacturing technologies and Product development , Polytehnic Univ of Valencia , Spain  Agenda 1 Personal presentation and Value proposition 2 Portfolio 3 My vision for NPD @ R&D performance @ Growth mindset 4 How ? Framework and Product Life Cycle  My value proposition  Mechanical Design & 3D CAD Engineering(Solidwork Expert) ‘’Think and act like an R&D Manager , not just a CAD engineer ‘’ - 3D mechanical design in SolidWorks (parts & assemblies) , IP protection classes (IPX4–IP68) 2D technical drawings compliant with ISO / ASME standards Tolerance stack-up analysis Deliver production-ready CAD, drawings, and BOM DFMA analysis (Design for Manufacturing & Assembly) , Design for , plastic Injection Molding, Die Casting, CNC, Sheet Metal Design optimization for cost, manufacturability, and reliability Integration of electronics, PCB, connectors, seals, gaskets and fasteners  My career path Process Engineer Plastic injection molding Zinc & Aluminum die casting Product development engineer 3D /2D Mechanical development of : biometric devices , Technical lighting , Electro Analitical devices Year  2001 ..... 2015 ... Industrialization Manager , NPLM Product industrialization @Automotive sector Product development Team management ,Department coordination KPIs reporting 2020 ... Consultance R&D Management Team management Leadedrship KPIs Management Department Coordination ...today  Portfolio examples 3D Mechanical design from Concept to Production (Solidwork) Product : Portable Photocolorimeter  Outdoor Electronic Enclosure – Injection Molded, IP 67 rated Application: Water quality analysis (Ammonia measurement) from 0.0 to 100.0 mg/L (ppm) Project scope and contribution  End-to-End Product Development Mechanical design from concept to production, including enclosure, internal architecture, and assembly strategy.  Electro-Mechanical Integration Seamless integration of optics (lens, cuvette), PCB, LCD, keypad, battery system, and sealing elements.  Design for Manufacturing & Assembly (DFMA) Optimized for plastic injection molding, assembly efficiency, and cost-effective mass production.  Industrialization & Validation Tolerance stack-up, material selection, manufacturing feasibility, and production-ready documentation  Reliability & Usability Focus Robust enclosure design, serviceability, ergonomic layout, and protection against environmental exposure.  Portfolio examples 3D Mechanical design from Concept to Production (Solidwork) Product : SECURMATE Molded, IP 64 racted Smart Entrance Sensor Indoor Electronic Enclosure – Injection Application: Access monitoring / presence detection for building and industrial environments Project scope and contribution  Mechanical Design from Concept to Production Complete enclosure and internal architecture design, optimized for compact form factor and reliable assembly.  Electronics & Sensor Integration Mechanical integration of PCB, sensing elements, connectors, battery compartment, and fastening system.  Design for Manufacturing & Assembly (DFMA) Plastic injection–optimized design focused on reduced part count, easy assembly, and cost efficiency  Reliability & Environmental Protection Robust housing design ensuring mechanical stability and protection against dust and handling stresses.  Industrialization-Ready Documentation 3D/2D drawings, tolerances, BoM, and manufacturing feasibility for series production.  Portfolio examples 3D Mechanical design from Concept to Production (Solidwork) Product : Superflat LED luminaire Mounting: Surface Lamps description: TOP LED 60W 3000K CRI 80 Description : Slim, efficient LED lighting engineered for manufacturability, performance, and visual comfort Project scope and contribution  Mechanical Design from Concept to Production Complete mechanical architecture of a superflat luminaire, optimized for easy asasembly and meiantainance  Optical & Thermal Integration Designed internal guides and housing geometry to ensure optimal luminous flux, visual comfort, and heat dissipation..  Design for Manufacturing & Assembly (DFMA) Components optimized for extrusion, injection molding, and efficient assembly with reduced part count. Material & Process Optimization Selection and validation of extruded aluminum and injection-molded plastics (PA66, PC) for durability, thermal stability, and cost efficiency.  Portfolio examples 3D Mechanical design from Concept to Production (Solidwork)  Industrial connectors Product: Industrial Connectors – Hoods & Housings Application: Harsh-environment electrical connectivity (industrial, automation, machinery) •Mechanical Design from Concept to Production Design and development of connector hoods and housings in plastic and zinc die-cast for industrial applications. •Environmental Protection & Compliance Designed to meet IP6x protection, ensuring resistance to dust, contaminants, and harsh operating conditions. •Structural Strength & Vibration Resistance Robust mechanical architecture with locking levers to ensure secure mating under vibration and mechanical loads. •Electro-Mechanical Integration Integration of inserts, contacts, grounding paths, cable clamps, and sealing elements into a compact, serviceable system. •Design for Manufacturing & Assembly (DFMA) Optimized for injection molding, zinc die casting, and efficient assembly, with focus on reliability and cost control.  Portfolio examples 3D Mechanical design from Concept to Production (Solidwork) Products: Adjustable / Tiltable/Sealing Suspended LED Spotlight Application: Architectural and technical lighting for residential and commercial spaces •Mechanical Architecture & Kinematics Design Designed the complete mechanical system including rotating and tilting mechanism, ensuring smooth adjustment, positional stability, and repeatability. •Optical Guidance & Beam Control Integrated optical guides and housing geometry to achieve controlled beam angles, precise light direction, and high visual comfort. •Thermal & Structural Integration Optimized heat dissipation through extruded aluminum profiles while maintaining a compact and robust form factor. •Design for Manufacturing & Assembly (DFMA) Components optimized for extrusion and injection molding, with simplified assembly and reduced part count. •Installation & Serviceability Designed for ceiling integration with clear mounting interfaces, easy installation, and maintenance access.  Portfolio examples 3D Mechanical design from Concept to Production (Solidwork) Product: Adjustable / Tiltable LED Spotlight Application: Architectural and technical lighting for residential and commercial spaces •Mechanical Architecture & Kinematics Design Designed the complete mechanical system including rotating and tilting mechanism, ensuring smooth adjustment, positional stability, and repeatability. •Optical Guidance & Beam Control Integrated optical guides and housing geometry to achieve controlled beam angles, precise light direction, and high visual comfort. •Thermal & Structural Integration Optimized heat dissipation through extruded aluminum profiles while maintaining a compact and robust form factor. •Design for Manufacturing & Assembly (DFMA) Components optimized for extrusion and injection molding, with simplified assembly and reduced part count. •Installation & Serviceability Designed for ceiling integration with clear mounting interfaces, easy installation, and maintenance access.  Portfolio examples 3D Mechanical design from Concept to Production (Solidwork) Product : Biometric Access Control Devices Application: Secure access systems using fingerprint identification (doors, walls, embedded installations) Project scope and contribution  Mechanical Design from Concept to Production Complete enclosure and internal architecture for door-mounted, wall-mounted, and embedded biometric devices.  Electro-Mechanical & Mechatronic Integration Integration of fingerprint sensors, PCB, actuators, mechanical clutch systems, connectors, and fastening elements.  Design for Manufacturing & Assembly (DFMA) Injection-molded and machined components optimized for part reduction, assembly efficiency, and cost control.  Modularity & Installation Flexibility Universal mechanical interfaces enabling multiple mounting options (surface, wall-embedded, door systems).  Industrialization-Ready Documentation 3D/2D drawings, tolerances, BoM, and manufacturing feasibility for series production.  Case study R&D Management Consulting R&D Transformation –Industrial connectivity Role: R&D Manager |2024 -2025 Company: HARTING , Sibiu Romania , https://www.harting.com/en-RO Scope : 56 engineers | 29 projects | €10M+ portfolio Client Challenges: • Poor milestone predictability • Late risk detection and weak DFMEA outputs • High pressure on cost reduction without suitable methodoogy • Leadership and ownership gaps • High internal friction caused by unclear Roles &Responsibilities and ineffective communication Actions delivered Measured Results Cultural & mindset change (ownership, transparency) I mplemented DFMA & early validation framework Moldflow, 3D printing) Introduced Go/No-Go milestone governance Built onboarding & structured technical training (FEM, +25–35% improvement in first-pass type test success rate −30–40% post–design freeze changes +20–25% earlier risk identification +15–20% improvement in milestone delivery predictability −15–25% reduction in late rework Structured DFMEA/PFMEA and FOT validation buffers Consulting Value This case demonstrates my ability to stabilize high-pressure R&D environments, reduce technical and delivery risk, and improve outcomes without slowing innovation. I now apply the same structured, pragmatic approach as an R&D consultant to help organizations improve product development performance, quality, and predictability  Case study R&D Management Consulting Role: Competence Center Manager/R&D Consultant |2021 -2024 Company: Guentner , Sibiu Romania , https://guntner.com/en-us Scope : Transform engineering into a scalable, cost-efficient, and performance-driven competence center capable of supporting growth, innovation, and predictable product industrialization Client Challenge: •Fragmented engineering organization across departments •Manual, repetitive engineering tasks with unclear ownership •Paper-based production documentation and inefficient Kanban & warehouse flows •Low motivation among engineers due to operational overload Actions delivered Cultural & mindset change (ownership, transparency) Built and structured an Engineering Competence Center with clear roles, ownership, and KPIs Standardized and automated engineering processes to eliminate nonvalue-added work Implemented Lean Six Sigma, poka-yoke, and digital work instructions Introduced KPI-based performance management and transparent reporting Implemented structured industrialization flows for new product launches Consulting Value •Engineering transformed from a cost center into a performance driver •Clear ownership, transparency, and measurable execution across teams •Reduced operational waste while increasing output and quality •Scalable organization ready to support future growth and NPD programs Measured Results €200K/year cost reduction by standardizing engineering activities (Electrical diagram engineers reduced from 6 → 2–3) €70K/year savings through digitalization and elimination of paper-based processes Increased production output via cycle-time reduction and process simplification Scrap reduction through improved quality checks and digital work instructions Improved operator performance via effective on-the-job training Higher engineering efficiency, motivation, and accountability Improved readiness for new product launches and innovation programs  My vision for New product development @ R&D performance @ Growth mindset 1. Strategy deployment 2. Framework @ Product lifecycle 3.Core values @ Communication 4. Collaboration @Partnership 5. Performance Management @ KPI Strategic planning..... VOC integration .... Early risk assesment ...Ownership , Motivation ..Growth Mindset  How ? Framework @Product lifecycle Strategy planning G0 Product roadmap and KPI Initiation phase G1 Concept development G2 Opportunity approved Concept aprooved  Inputs Mission and Vision , Goals and objectives , VOC Voice of the customer , Product specifications Technology Roadmap , Risk evaluation Cost , time and quality targets Patents infringements ,Testing plan , Product development G3 Design freeze Product Validation G4 Type test passed Industrialization G5 Production launch G6 Production process approved PPAP approved  Outputs Projects , KPIs , Technology roadmap , Project charter, Risk mittigation plan , Prototype validation plan DFMEA , PFMEA , Tolerance calculations , FEM , Type test 3D /2D drawings ,BoM , FOTs Measurement report ,Manufacturing feasibility Design validation , Process flow , Production layout , PPAP Conclusion  Structured Approach R&D roadmap provides a structured method for managing R&D projects effectively. Stage-gate NPD, clear milestones, VOC-driven requirements, and KPI-based execution  Risk Minimization Each project phase builds on the last to minimize risks and avoid project failures. Early DFMEA/PFMEA, DFMA, FEM simulation, and validation to prevent late-stage failures  Maximized Project Success Growth mindset mentality helps maximize project success by ensuring high-quality and efficient outcomes. Faster time-to-market, lower cost, higher first-pass success, and higher innovation rate