Expert Details

Expert in Fact-Based Problem Solving: DoE, Taguchi, ISO 9002, Weibull, Manufacturing Cost Control, Design

Expert ID: 720833 Wisconsin, USA

Request Expert

Expert is concerned with controlling manufacturing costs and improving product quality through fact-based decisions, including design of experiments, statistical process control, and similar techniques. His A2Q Method(TM) was used to simultaneously develop a new heat exchanger and the production procedures for it. He enjoys integrating these approaches in factory environments to solve industrial problems. Application of his A2Q Method dramatically improved a paint system for a major bicycle manufacturer.

Expert has found that communication of results is as important as generating those results. He not only develops graphic interpretations of both simple and complex analytical results, he has found effective ways to train others in useful graphical methods.

Expert has demonstrated fact-based methods in manufacturing, product design, business analysis, and service activities. He has taught courses in statistical design of experiments as well as Taguchi methods.

The application of Expert's A2Q Twelve Step Plan(TM) has solved a wide range of industrial materials and process issues. Recently, he helped a small firm learn to make heat guns (industrial strength hair dryers) with improved temperature control, without expensive electronics.

Expert has led a small firm through to ISO 9002 certification. He was also an examiner on the Wisconsin Forward Award (an adaptation of the Baldrige Award) Board of Examiners in 1998.

Expert has used Weibull analysis for product development and reliability evaluations. Examples include development of a heat exchanger for military applications and evaluation of high reliability switches.

Expert implemented new product production using aluminum vacuum brazing and developed new aluminum vacuum brazing alloys and techniques. He also developed a practical qualification procedure for aluminum ultrasonic soldering.

Develop and implement an Operations/Quality manual for a 14-person independent distribution firm. Identify efficiency opportunities and develop improved business analysis tools and methods.Analyze a massive production information database, identify product improvement opportunties, and analytical procedures for same. Simultaneously develop product monitoring and record-keeping methods for on-going product improvement analyses.Document operations procedures, develop Operations/Quality manual for a small (five people) factory product/service firm. Simultaneously set up a computer database system for _effective_ corrective/preventive action records.Instruct a major firm's large division in 6-Sigma methods (DoE & RSM portion), direct multiple projects using DoE methods.Direct and facilitate the development of a new product, using a new (to them) material and process. Set up the development plan and schedule, implement 'self-healing' production monitoring, plus continuous improvement methods, encourage and bring out technicians' improvement contributions.

Expert may consult nationally and internationally, and is also local to the following cities: Chicago, Illinois - Rockford, Illinois - Aurora, Illinois - Naperville, Illinois - Joliet, Illinois - Elgin, Illinois - Milwaukee, Wisconsin - Madison, Wisconsin - Kenosha, Wisconsin - Gary, Indiana

Request Expert

Education

Year Degree Subject Institution
Year: 1972 Degree: PhD Subject: Metallurgy Institution: Iowa State University
Year: 1966 Degree: MS Subject: Metallurgy Institution: Iowa State University
Year: 1964 Degree: BS Subject: Physics Institution: University of Massachusetts - Amherst

Work History

Years Employer Title Department Responsibilities
Years: 1987 to Present Employer: Undisclosed Title: Principal Scientist Department: Responsibilities: Guide resolution of client product and productivty issues. Design and implement client Quality/Operations systems. Analyze client product data and improve product quality & value.
Years: 1987 to 1998 Employer: Milwaukee School Of Engineering Title: Professor Department: Responsibilities: Instructed undergraduates in metallurgy, advanced statistics, thermodynamics, and other subjects as needed.
Years: 1980 to 1987 Employer: Allen-Bradley Company Title: Manager, Principal Scientist Department: Metallurgy and Physical Test Lab Responsibilities: Directed materials lab and resolved materials issues.

Developed corporate & employee capability in Taguchi Method(tm) statistical analyses.
Years: 1979 to 1980 Employer: Modine Manufacturing Company Title: Chief Engineer Department: Responsibilities: Directed development of new heat exchangers, most notably, the Beta-Weld Radiator.
Years: 1974 to 1979 Employer: Aluminum Company of America Title: Senior Engineer Department: Responsibilities: Developed new brazing alloys. Served as customer liason for brazing. Refined vacuum brazing process capability. Reduced alloy proliferation and costs.
Years: 1972 to 1974 Employer: Carnegie-Mellon University Title: Research Fellow Department: Responsibilities: Developed software for thermodyanmic/phase diagram calculations. Directed the production of a one-hour, color film for instuctional purposes.

International Experience

Years Country / Region Summary
Years: 1987 to 1987 Country / Region: England, UK Summary: Introduce Taguchi Methods (tm) [i.e., DoE] to an electronic manufacturing firm. Direct/facilitate multiple projects using these methods.
Years: 1995 to 1995 Country / Region: Czech Republic Summary: Instructed, using a hands-on example, the use of experimental design for enhancing customer demand for products.
Years: 1998 to Present Country / Region: Taiwan Summary: Develop processing and production layout for recovery of catalytic converter cores for recovery of precious metal content. Facilitate metal refining contracts

Career Accomplishments

Associations / Societies
Expert has been a member of both the American Society for Metals International (ASM Int'l) and the Metallurgical Society, American Institute of Mining, Metallurgical and Petroleum Engineers (TMS-AIME).

He has also been a member of the American Society for Quality (ASQ).
Licenses / Certifications
He is certified through the ASQ as a Certified Quality Engineer (CQE) and a Certified Quality Auditor (CQA).

In addition, Expert has been a Wisconsin Forward Award Examiner.
Professional Appointments
ASQ - Racine-Kenosha-Walworth Chapter, Treasurer, Publicity Chair.
Awards / Recognition
Expert received the Allen-Bradley Recognition Award for bringing Taguchi Methods to the Company.

He received the Trek Award of Appreciation (Application of the A2Q Method (tm) for optimization of ice colors at Trek).
Publications and Patents Summary
Expert has produced 23 publications on statistics applications & metallurgy.

Additional Experience

Expert Witness Experience
Deposed as expert witness in a case involving aluminum vacuum brazing processing.

Expert has performed complete analyses in preparation for cases involving metal performance more than four times.
Training / Seminars
Expert is involved with several seminars/training courses. They are Introductory Applied Statistics, Solving Technical Problems with the A2Q Method (tm), and Design of Experients - Applied. This last course requires each student to complete three projects, one of which is done individually.
Marketing Experience
Develop and analyze survey to determine optimum product placement and feature set. Expert has done this three times, twice for an industrial product and once for a consumer product.
Other Relevant Experience
Wisconsin Forward Award Examiner.

He has taught one course in introductory statistics and applications for MBA students at Cardinal Stritch University.

Language Skills

Language Proficiency
German Proficiency: minimal. Give me 6 weeks and an honest need to recover it.

Fields of Expertise

Request Expert

Dev Tool:

Request: expert/fact-based-problem-solving-doe-taguchi-iso-9002-weibull-manufacturing-cost-control-design
Matched Rewrite Rule: expert/([^/]+)(?:/([0-9]+))?/?$
Matched Rewrite Query: experts=fact-based-problem-solving-doe-taguchi-iso-9002-weibull-manufacturing-cost-control-design&page=
Loaded Template: single-experts.php