Bill Sampson Email and Phone Number

I am assigned as Principle Investigator on several key development contracts including Fire Suppression Technology and Caseless Ammunition. Developed a gas generator based fire suppression system from concept to production ready status. This effort included: development of a new gas generant compound, development of the generator components and gas cooling system, optimization of the combustion system to minimize toxic effluents in order to obtain an EPA SNAP approval for occupied spaces, and passing all UL requirements to obtain a product listing under NFPA 2010. I also designed, constructed and obtained a separate UL listing for an electronic interface to initiate the gas generators from standard fire releasing panels. I proposed a new method for manufacturing caseless ammunition cartridges using explosives injection loading technology. Received a DOD contract and developed this technology through successful demonstrations in a 5.56mm cartridge.

This position was responsible for all aspects of site operations. All other functional managers reported to this position. I managed a staff of professional and operations/technical personnel. This site had the best budget, schedule, quality and safety record of all TRW Automotive plants during this time period. This accomplishment was achieved during the time period after which the plant closure had been announced. Key objectives met during the shutdown included retention of personnel, maintenance of safety records, employee morale, build out of production, decommissioning of plant and equipment, and environmental cleanup of the site.

I advanced to a newly created group, Global Manufacturing Engineering. This group was responsible for project management of technology transfer and product launch assistance within the automotive group of TRW. I completed an assignment as project manager of a $2M technology transfer to a third party. I was also responsible for all production processes and improvement recommendations. I managed all process trouble shooting activities and directed operations of the facilities, engineering, and testing groups for the plant. Tracked and reported department budgets, and metrics.

I was tasked with developing plans for future R&D and propellant production at TRW. Manufacturing options were investigated resulting in a recommendation for a new facility. Conducted a search for and evaluated 9 properties. Recommended Sparks, NV site, performed due diligence, and prepared a business plan and justification. Pursued and received corporate approvals and funding ($11M). I relocated to the site with one other person then jointly prepared the site by; repairing/expanding infrastructure, installing new facilities and equipment, obtaining all business and operating permits (e.g. EPA, BATF, C of O, county, state, etc.), building long term relations with state and county agencies, and developing a site plan for short term and long term (production) requirements. I then developed a multi-purpose process for new generation airbag propellants, and designed, constructed, and commissioned a pilot facility in 9 months. I successfully processed a new generation propellant, passing all production and quality requirements within all schedule targets. Submitted a plan for scale-up and received approval and funding ($22M) for a complete production plant based on the pilot design.

I was assigned as the corporate wide technical resource on propellant, processing, production and process development. Responsibilities include locating and acquiring technologies from competitors and non-air bag industries for application to TRW processes and products. This position assisted in long range strategic planning for future air bag products. This position required direct communication with upper management, customers, and applications/sales through formal presentations, reports and video conferences.

Designed and implemented a high capacity (> 1M pounds/year) air bag propellant production facility. This task involved evaluating, specifying, procuring, testing and debugging of all process equipment. I also interfaced with and coordinated all contractors and engineering firms during construction. Unit operations included drying, grinding, blending, agglomeration, bulk material storage, pneumatic conveying and bulk material handling. The time line from conception to first production was 14 months.I was responsible for the development and implementation of all new propellant process equipment and process techniques. Developed, designed, and installed new technology for agglomeration of air bag propellants. I was assigned as Project Mgr. for the $1.5M follow up production agglomeration system. This project required developing the process P&ID's, equipment specifications, layout drawings, control system, process safety management, etc. Developed and implemented a waste treatment system for air bag propellants.

Responsible for production support on all composite propellant programs, pilot plant design, R&D computer system operations, technical support of air bag operations, and electronics design and fabrication. This group consisted of 9 engineers and 9 technicians.Designed, constructed and operated the first continuous twin screw extruder propellant processing plant in the USA.

Operated the electronics design laboratory for the R&D directorate. Designed and fabricated several microprocessor controlled specialty circuits for use in research. Chief technical consultant for processing of pyrotechnics for automotive air bag systems. Involved in the design, construction and commissioning of several new process facilities. Conducted DOE's on process improvements. Researched, designed, constructed and operated pilot plants to produce: iron linoleate, synthesize spherical HMX explosive, and to treat explosives wastewater streams.