Manufacturer of continuous fiber-reinforced thermoplastic composite tapes• Created multiple process and equipment improvement ideas, as well as new methods for setup of production line and testing of product, for use by Production operators and Maintenance technicians• Responsible for planning and execution of all engineering trials in company for over 5 years, covering multiple grades of glass and carbon fibers, as well as PPS, PEI, PC/ABS and other engineering resins as well as… Show more Manufacturer of continuous fiber-reinforced thermoplastic composite tapes• Created multiple process and equipment improvement ideas, as well as new methods for setup of production line and testing of product, for use by Production operators and Maintenance technicians• Responsible for planning and execution of all engineering trials in company for over 5 years, covering multiple grades of glass and carbon fibers, as well as PPS, PEI, PC/ABS and other engineering resins as well as several resin additives. Supervised multiple plant floor operators during trials• Managed major capital project involving purchase, modification, integration and commissioning of 1.75" plastics extruder• Major participant in multiple other capital upgrade projects, in specifying requirements and assessing suppliers, then in integration and commissioning of new equipment (dies, extruders, weigh blenders, dryers)• Developed process for carbon-PPS product which brought it from failing engineering trial to successful commercial production• Developed process and product for customer based on their performance specs; technology then licensed to customer• Responsible for issuing changeover task lists and process parameter sheets for dozens of products across 3 extrusion lines, for 7 years• Created extensive library of training materials for operators, for inclusion in ISO 9001 database and for technology transfer to new plant• Following DMAIC methodology, added instrumentation to process equipment to identify poorly performing tooling and heaters, to give evidence to get Maintenance department to fix them• Created Production data entry forms in Excel (formerly paper-based), with spec-based warnings and alarms and charting, using Visual Basic• Developed tensile, shear and flex testing methods on Instron mechanical lab tester, based on ASTM standards• Experience with Filemaker database, Omron vision systems, Keyence displacement sensors, WinSPC, Minitab, Kepware, Autocad Show less

* Made major update to screw torque and throughput specifications for small tonnage PET injection molding machines, based on a large self-designed and executed experiment, restoring confidence of sales engineers in their sales tools* Built Excel tool to predict level of degradation byproduct in final polymer part, giving insight into where in hot runner the degradation reaction occurs* Kicked off two major technology investigation projects aimed at cycle time reduction in PET preform… Show more * Made major update to screw torque and throughput specifications for small tonnage PET injection molding machines, based on a large self-designed and executed experiment, restoring confidence of sales engineers in their sales tools* Built Excel tool to predict level of degradation byproduct in final polymer part, giving insight into where in hot runner the degradation reaction occurs* Kicked off two major technology investigation projects aimed at cycle time reduction in PET preform injection molding, and led cross-functional teams through initial feasibility testing* Created novel feed screw design for PP pail injection molding machine, which was accepted by fickle customer* Designed multiple industrial experiments for efficiency in use of machine time, instrumentation, resin consumption, and analysis effort; liaisoned with shop floor operators to gain their insight and buy-in to experimental plans, ensuring successful execution Show less

* Successfully redesigned choke bar configuration for 4 m (13 ft) wide T-slot sheeting die, resulting in flatter sheet and improved product quality* Evaluated design of 3 layer coextrusion sheeting die in use in Pilot Plant, and determined that core layer choke bar could not be eliminated from scaled-up design* Created 3D simulation model of 4 m wide sheeting die, giving insight by flow visualization into possible origin of visual defect in product* Simulated 12" vented single screw… Show more * Successfully redesigned choke bar configuration for 4 m (13 ft) wide T-slot sheeting die, resulting in flatter sheet and improved product quality* Evaluated design of 3 layer coextrusion sheeting die in use in Pilot Plant, and determined that core layer choke bar could not be eliminated from scaled-up design* Created 3D simulation model of 4 m wide sheeting die, giving insight by flow visualization into possible origin of visual defect in product* Simulated 12" vented single screw extruder to check proposed feed screw redesign for possibility of vent flow.* Participated in Pilot Plant extrusion trials studying fibre orientation in sheeting die and measurement of dynamic lip gaps Show less

* Created a single-screw extrusion simulation software package for industrial and academic use, which reproduces the performance of barrier screws well* Assessed profile extrusion technology patents for woodfibre-plastic composites, aiding a customer's decision to stop using a licensed proprietary technology* Analyzed bubble dynamics in a LDPE blown film line for a major U.S. resin producer, advancing their program to link process conditions with product properties* Analyzed and… Show more * Created a single-screw extrusion simulation software package for industrial and academic use, which reproduces the performance of barrier screws well* Assessed profile extrusion technology patents for woodfibre-plastic composites, aiding a customer's decision to stop using a licensed proprietary technology* Analyzed bubble dynamics in a LDPE blown film line for a major U.S. resin producer, advancing their program to link process conditions with product properties* Analyzed and provided design recommendations for several spiral, flat, and profile die designs, for both for monolayer extrusion and coextrusion* Raised company standards for consulting work performed and software products generated Show less