Industrial, Manufacturing, Operations Expert Consultant Resume

Providing industrial engineering consulting, manufacturing engineering, operations research, project direction, engineering, failure analysis, forensic engineering and related expertise to a wide variety of clients.

Development of a SPC system for monitoring the quality of incoming materials for a manufacturer of food products. Use of regression analyses and other statistical methods to determine important factors affecting the reliability of micro tests. These tests determine whether yeast or mold is present in processed food. Development of a model to estimate the yield of welds with respect to porosity criteria. The model uses detailed pore measurements from X-rays. Design and analysis of experiments to estimate the effect of critical factors on porosity in welds. Statistical analyses of performance data produced by a neural-net classifier of weld defects. Developed a method for selecting welds for training the neural net. Member of a team performing assessments of supplier operations to improve the total quality of joining operations. Responsibilities emphasized production control, cost analysis, standard times, statistical process control and other industrial engineering functions. Completed assessments for thirty-one companies. Development and use of simulation models to determine resource requirements for a repair shop, lot sizes for a job shop, kanban sizes for a lean manufacturing system, and software requirements for an information system. Developed simulation software so that client avoids purchasing a commercial simulation package. Analysis of quality data for a weld cell producing automobile door frames. The analysis identified significant variables causing dimensional variability. By focusing on these variables, the manufacturer reduced scrap and rework by 15%. Analyses of an assembly line that produces shrink-wrapped gift sets. The analyses included detailed time studies of each operation. The analyses produced specific recommendations for improving productivity by method changes and improved balancing of tasks. The line productivity doubled. Development of a model to estimate the probability of complete fusion based on critical variables such as fixture runout, weld width and beam alignment. Results from the model have improved weld quality by identifying requirements for maximum fixture runout. The sponsor funded the development of a computer program to facilitate model calculations. Development and teaching of short courses in the areas of production control, statistical process control, regression analysis and product reliability. Bradken Marion Corporation, Marion, Ohio Simulation modeling of a robotic cell to produce molds Battelle Memorial Institute, Columbus, Ohio Simulation modeling and analysis of nuclear waste repositories Ross Laboratories, Columbus, Ohio Developed an algorithm for scheduling their batch-oriented manufacturing process Battelle Memorial Laboratories, Columbus, Ohio Assisted in the development of a reliability analysis program for a nuclear waste disposal facility CVI Corporation, Columbus, Ohio Reliability analyses of cryogenic systems Ranco Corporation, Columbus, Ohio Reliability analyses of control systems Rubbermaid Corporation, Wooster, Ohio Developed simulation models of conveyor lines Professor Emeritus in the Industrial, Welding and Systems Engineering Department, a major research university

Appointed Research Associate, Assistant Professor, and Associate Professor. Was responsible for courses in system simulation, manufacturing systems, stochastic processes, and queueing theory. Funded research projects: Development of estimators for standard times using operational shop floor data (Funded by AT&T). Reduction of gear manufacturing throughput time (Funded by IIT Research Institute). Development of welding cost models (Funded by Edison Welding Institute).

Sabbatical to formulate requirements for a decision support system using simulation in a CIM environment. Performed extensive interviews of manufacturing management at both IBM and other company plants to gather inputs for these requirements.

Director of University Urban Mass Transit Research and Training Grant. Project to recommend policies for commuter aviation in Ohio. Project to develop optimization methods for abating mine drainage pollution. Projects to develop a regional flood-plain management simulation model and to determine cost-effective engineering techniques for use in flood-plain management. Project to plan the development of a water resource management system for Ohio. Project to develop a computer mapping system for water resource planning. Projects to develop a high-resolution combat simulation of mobile battalion engagements. The Army used this model to evaluate equipment performance, tactics, and organizational structures for armored battalions. Formulated a stochastic combat model which was used by the Army to extrapolate the results for a small-unit combat simulation in a large-unit model.

Responsible for developing analytical methods for predicting the relationship between reliability growth and development effort for advanced rocket engine systems (two years). Responsible engineer for the Atlas reliability engineering effort and for coordinating the reliability program with the Atlas program office.

Performed process quality and engineering economy studies.