As an Application Development Engineer, I work to develop and leverage engineering relationships with OEM’s and customers to identify opportunities for Azdel materials in my focus area, which includes Trunk Trim (deck lids – luggage sides – spare tire covers – lift gates), SUV Quarter Trim Panels, Seat Backs, and Door Trim (panels - bolsters - map pockets). I provide pre-production engineering support for awarded programs to minimize risk during SOP to ensure a successful launch. I assist the Product Development team by evaluating / validating new material advancements that improve product performance and reduce cost. I work with the OEM’s to ensure our materials meet their performance specification and help drive future use when applicable. I develop marketing and engineering support tools, such as process design guidelines, product positioning guides and general material performance outlines.

As Azdel’s Technical Service Manager I manage multiple employees to provide customer support to Tier 1 and 2 molders that supply GM, Ford, Chrysler, Toyota, Honda, Hyundai, Nissan and Tesla. These molders produce many automotive interior and exterior products, including headliners, rear window trim, package shelves, load floors and under body shields. I assist these domestic and international customers in Japan, South Korea, China, Thailand, Australia, Mexico and Canada in material selection, tool design and process recommendations in order to meet OEM performance and aesthetic requirements. Internally I helped specify multiple pieces of process equipment (Rotary thermoformer, Lamination press, Infra-weld and Sonic-welding equipment) and validation tools (headliner, underbody, torture) used to test new material formulations prior to customer introduction. I have assisted in developing five new material grades with reduced weight and improved mechanical performance that led directly to winning business with Honda, Hyundai, Toyota, GM and Ford.

Within the lab my responsibilities included developing new products, product formulas, or process improvements on a continuous basis. I worked daily with Raman Microscopy, DSC and TGA analysis equipment. I developed a nondestructive method using Raman Microscopy to determine phthalate levels within a PVC membrane. This was a major hurdle of the company to address cause of high warranty work on product failure in the field.

I was responsible for the North American thermoforming research laboratory. Equipment included a video microscope, Spectrophotometer, Tensiometer, Melt flow index machines, Mocon OTR tester. Lab machinery included 4 thermoformers, two vertical presses, one match metal trim-press, and an ultrasonic welder. This equipment and machinery was used to evaluate process conditions on prototype tooling and help set process parameters on the plant floor. They were also used to provide customers with processing solutions or test market sales samples. As the company's project leader I accomplished launching a new product line for one of our customers which required the matching of components between two separate processes including 5 injection molding tools (three products) and 3 thermoforming tools (three products). During the 6 years with Huhtamaki, I successfully oversaw the launch of more than 30 new products with responsibilities for product, tooling and process design, quality procedure plans (SPC) and internal plant launch strategies for our customer’s new products. Customers included General Mills, Hormel, Kelloggs and SC Johnson. For 2 years I served as the Quality Manager of the Coleman plant overseeing 3 supervisors and 24 inspectors. I hold numerous mutual design patents on SC Johnson’s Ziploc® thermoformed PP container product line.

Responsibilities included managing thirteen employees in three separate departments; Extrusion: Dry blend PVC for blown film applications, machinery included a Cincinnati Milicron 55 twin screw extruder. Bandcasting: Required mixing of additives including, waxes, stabilizers, lubricants and plasticizers for each individual resin formulation using the solvent THF. This operation consisted of three lines including a four-bed solvent recovery system. Finishing: Consisted of several slitting and rewinding machines. This position Included responsibilities for product quality, packaging and shipping.

Position responsibilities included the setting of process conditions for twenty-eight injection molding machines and countless molds. I used numerous trouble shooting methods including Ishikawa, 8D's and SPC. Researched and made recommendations for process improvements including new resins, suggested mold design changes, completed new tooling evaluations as well as equipment try-out (molding secondary). Completed cost efficiency proposals both internally and with external customers throughout the automotive industry including Saturn, Ford and Mazda. Assisted company with implementing a QS-9000 system, including APQP and PPAP. I have experience with processing and troubleshooting the following materials; ABS, GF-ABS, Nylon, GF-Nylon, PC, PCABS, PE, PP, PPO, PS, Rigid and flexible PVC.