Expert Details

Expert in Materials Technology, Powder Metallurgy, Advanced Ceramics, Process & Product Development, R&D, Lean

Expert ID: 731984 New Hampshire, USA

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25+ years of experience in successfully managing and spearheading R&D and Operations projects to completion. Developed new products and processes, led cross-functional teams, project management and implementation, mentored subordinates and peers, provided team building and leadership, problem solving skills, and solutions to customers. Hand-picked by all employers to work on the key R&D projects. Developed high-cap tester, advanced termination equipment, improved sensor yields, launched Mercury CEMS, optimized sapphire crystal growth processes, implemented lean methodology to many projects and more. Subject matter expert in Materials Science & Engineering with Bachelors, Masters and Doctorate degrees from the Indian Institute of Technology Bombay, India. Worked as a Research Faculty and Post-Doctoral Scholar at the Pennsylvania State University, USA. Author of 70 peer reviewed papers in international journals and conference proceedings. Inventor of 5 patents in India, USA and Taiwan.

Expert may consult nationally and internationally, and is also local to the following cities: Boston, Massachusetts - Worcester, Massachusetts - Springfield, Massachusetts - Lowell, Massachusetts - Cambridge, Massachusetts - Brockton, Massachusetts - New Bedford, Massachusetts - Hartford, Connecticut - Manchester, New Hampshire - Providence, Rhode Island

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Education

Year Degree Subject Institution
Year: 1995 Degree: Ph.D. Subject: Metallurgical Engineering & Materials Science Institution: Indian Institute of Technology Bombay (IIT B)
Year: 1987 Degree: M.Tech. Subject: Metallurgical Engineering, Specialization: Materials Technology Institution: Indian Institute of Technology Bombay (IIT B)
Year: 1984 Degree: B.Tech. Subject: Metallurgical Engineering Institution: Indian Institute of Technology Bombay (IIT B)

Work History

Years Employer Title Department Responsibilities
Years: 2013 to 2014 Employer: RdF Corporation Title: Senior Process Engineer – R&D Department: Responsibilities: Managed and led the R&D and process improvement projects for the Special Products department. Led the process and product development, process control, optimization and standardization, and engineering documentation roles. Improved the manufacturing, calibration, and testing processes for the high temperature probes used in the nuclear industry applications to meet the most stringent design specifications and customer requirements.
* Improved the processes and production yields using SPC techniques root cause analysis, and failure analysis.
* Good hands-on experience in designing, process development, and manufacturing methods for surface, insertion and immersion temperature and heat flux sensors for demanding applications in the aircraft, aerospace, nuclear, shipboard, land vehicles, military, laboratory, commercial and industrial products.
* Good working knowledge of the AS9100 and ISO 9001 standards, and process engineering experience in carrying out operations under contemporary design, manufacturing and quality systems.
Years: 2012 to 2012 Employer: Advanced Renewable Energy Company Title: Senior Process Engineer Department: Responsibilities: Developed, optimized, and made significant process improvements to the Controlled Heat Extraction System (CHES) furnace technology and processes for producing large diameter bulk sapphire single crystal boules with unique c-plane growth specifically for the light emitting diode (LED) applications. Played a key role in process technology development and made great advances for systematically improving the recipes and production processes for manufacturing high quality sapphire single crystal boules free from all the major defects such as bubbles, cracks, grain boundaries, twin boundaries, metallic inclusions, and any other types of macro and atomistic defects using the CHES furnace technology.
* Developed, set up and managed the Excel/Access databases for systematically and meticulously tracking and monitoring the hardware and process components of the crystal growth production process which was very useful in correlating the single crystal growth characteristics to the hardware design changes and process parameters and helped several projects across the company.
* Implemented the design of controlled experimental plans to improve crystal quality and provided technical support to the modelling and process teams by researching hard to find technical information in a timely fashion.
* Provided technical support to the Process Technology Group, Sustaining Engineering, and Product Support Group in the field.
* Made proven significant process improvements to the CHES technology for producing defect-free sapphire single crystals.
Years: 2005 to 2011 Employer: Thermo Fisher Scientific, Inc. Title: Senior Process Engineer / Sensor/Detector Scientist / Senior Project Engineer / Consultant Department: Responsibilities: Worked for Air Quality Instruments, part of the Environmental Instruments Division. Managed and led the manufacturing processes for sensors/gas detection products, Mercury CEMS, and Ambient Air Quality Monitoring Systems (AQMS) and improved the yield, performance, robustness, and reliability. Implemented techniques such as SPC, FMEA, CAPA, Six Sigma, Poka Yoke (Error Proof), Root Cause Analysis, and Practical Process Improvement (PPI) method, and added value by significantly improving the manufacturing processes for the Industrial Hygiene (IH) and Systems Integration (SI) value streams:
* Improved the yield from as low as 20-40% to 80-95% for different sensors and from 90% for the systems.
* Improved the productivity of the Sensor Lab by ~120% for manufacturing the same volume of
sensors, and reduced the number of operators and technicians from 12 to 5.
* Reduced the MRB scrap per year from > $110,000 to < $10,000 for sensors and gas detection products and from > $70,000 to < $12,000 for the systems integration value stream.
* Provided manufacturing engineering support for $10-12 million revenue per year for sensors and gas detection products and $20-25 million per year for mercury and systems for 6+ years.

Led and managed multiple projects, developed processes and products, conducted design of controlled experiments (DoE), provided process control and optimization, carried out engineering change order (ECO) and documentation, training, and customer applications. Developed innovative electrical test measurements and provided engineering solutions to complex technical problems for the sensor manufacturing processes. Improved the quality, performance and first pass yields for manufacturing catalytic bead/combustible gas and electrochemical sensors based on thermal transduction and oxidation-reduction modes, respectively. Provided technical consultancy and complete manufacturing engineering /support for the production of sensors and portable and fixed gas detection instruments for the IH value stream. Led root cause analysis for field failures, and provided technical support to supply chain management for the IH products. Provided technical leadership role to the sales/marketing teams by identifying the products to be discontinued (made obsolete) for either low volumes or hazardous nature for manufacturing, and transfer of the gas detection products from Calgary, Canada to Franklin, USA as part of consolidation.
* Led manufacturing engineering processes and took leader role in the plant layout and setting up of the production lines for the assembly and testing of Mercury Continuous Emission Monitoring Systems (Hg-CEMS).
* Led transfer from R&D development to pilot runs and PTR's for launching of the Mercury Freedom System.
* Provided technical leadership to the SI value stream for integrating the different gas analyzers, calibrators, probe controllers, probes, and accessories in a rack, shelter or other configurations (custom built to customer requirements) for continuous monitoring of mercury and other toxic gas emissions in the coal fired power plants, incinerators and cement plants.
* Improved design for manufacturability, adapted best lean practices, and continuous improvement (kaizen) processes for the air quality instruments (gas analysers, particulate/aerosol monitoring systems, Hg-CEMS, Multigas and Ambient AQMS) for monitoring stack gases, particulates and aerosols.
* Provided technical leadership to different cross-functional teams, ECO documentation, and training production staff for hazardous chemicals awareness and safe handling practices during assembly and testing.
* Technical project lead for transfer of Waldron products (probes, ambient systems, CEMS) to Franklin site as part of consolidation.
Years: 2001 to 2005 Employer: Electro Scientific Industries, Inc. Title: Senior Materials Scientist / Senior Engineer - R&D Department: Responsibilities: Collaborated with strategic customers, vendors, industry partners and cross-functional development teams and provided complete technology solutions to customers. Successfully presented product development work to key customers (muRata, Kyocera, Matsushita, TDK, Taiyo Yuden, Samsung, EPCOS, AVX, Kemet, Phycomp, Walsin, and Team Young) and at executive meetings (AVX and Kemet) and promoted new product development. Worked with product marketing managers for developing technology roadmaps and strategic product launches. Valued as a core member of R&D for marketing products to strategic customers. Promoted business significantly exceeding $30 million by technical presentations. Worked on several forefront and key R&D projects listed below:
* High-Cap Tester Research & Development: Project Manager from project inception, carried out basic and applied research including getting customer requirements, and developed high-throughput/speed high-cap tester (Model 3500).
* Electrical Contacts Research & Development: Project Manager/Research Lead for electrical contacts project for accurate dissipation factor (DF) measurement of NPO/0201/100pF MLCC's and meeting termination marking specifications.
* Advanced/Laser-Based Termination Research & Development: Developed innovative techniques for accurate placement of termination stripes (metallization) and wraparound with precision for fine-pitch, multi-element chip arrays, and evaluated techno-commercial feasibility for filing application patents and invention disclosures.
* Chip Termination Applications Research & Development: Project Manager from project inception, worked on NDA and JWA documents with key paste manufacturers and customers, optimized system parameters for Ag (Pb-free) and Cu pastes for different dielectric types, case sizes, and customer chips, and developed high-throughput termination system (Model 332).
* Additional R&D Projects involving different Materials and Divisions: Laser via drilling for the electronic interconnects, low-k dielectrics for microelectronics, MEMS, and RF devices, IC packaging for semiconductor and memory devices.Developed parametric and machine vision qualification test procedures for visual test systems, and documented manufacturing procedures for carrier belt tooling.
Years: 1998 to 2001 Employer: Pennsylvania State University, University Park, State College, PA 16801 Title: Research Faculty/Post-Doctoral Scholar Department: Materials Research Laboratory Responsibilities: Managed sponsored research projects independently, wrote project proposals, set up laboratory facilities, carried out independent research, completed projects on time, presented research work at meetings and conferences, and published papers in peer reviewed journals. Lectured students, conducted tests, assignments and seminars, and evaluated performance for the graduate courses: High Power Energy Storage (Mechanical Engineering), and Electronic Property Characterization of Materials & Capacitors (Materials Science & Engineering).
* High-Energy Density Capacitors: Developed antiferroelectric-ferroelectric (AFE-FE) phase switching materials based on rare earths modified PLZT compositions for high-energy density capacitors for electric car and electric ship (ONR/DOE sponsored PEBB program). Characterized AFE-FE capacitors for electrical properties in high power electronic applications.
* Microwave Sintering & Processing: Microwave sintering of P/M Cu and Ni-steels and evaluated mechanical properties. Basic studies on the microwave-material interactions by microwave coupling and thermal run-away response behaviour on electro-ceramic powders and coatings. Microwave processing of near-net-shape alumina-aluminum metal composites.
Years: 1991 to 1998 Employer: ACC Limited, Research & Consultancy Directorate Title: Deputy Manager - Research Department: Responsibilities: Managed and led various multi-disciplinary R&D projects from inception as part of diversification in the areas of Advanced Ceramics/New Materials. Set up world-class laboratory for research and development of advanced materials and novel processes for synthesis of advanced ceramic powders and products. Managed the research projects by leading cross-functional teams to meet customer requirements and business goals. Hands-on experience in R&D, pilot scale-up operation, project management, capital budgeting, costing and technical marketing for meeting deliverables on time. Managed several R&D projects by leading cross-functional teams and motivating team members to be on schedule and within budget. Have extensive experience in development, implementation, and management of Quality Management Systems in compliance with ISO 9000 standard. Successfully developed processes and products and tested feasibility to install commercial plant for the Advanced Materials Business Group in Calcutta, India.
* Developed innovative processes for high-purity barium titanate, alumina, and zirconia ceramic powders including BaTiO3 based MLCC and PTC thermistor formulations.
* Developed low thermal expansion ceramics, electronic grade ultra-fine reactive powders (BaCO3, TiO2, ZnO, Fe2O3) and transparent alumina ceramics for HPSV lamps.
* Developed custom products such as alumina substrates used in transponder circuit of satellites for ISRO, metallized vacuum interrupter tube for BHEL/BEL, armour plates for Defence, etc.
* Developed bio-materials: hydroxyapatite powders and granules, zinc phosphate and glass ionomer dental cements.
* Familiar with current Good Manufacturing Practices (cGMP), FDA regulations for testing of bio-materials and QA/QC process validation methods used in the pharmaceuticals industry.
* Developed product specifications and technical brochures for marketing of advanced ceramic powders and products.
* Designed continuous horizontal microwave system for ceramic powder processing and sintering.
* Inventor of 3 application patents for commercializing production of advanced ceramic powders for electronic and structural applications.
* Controlling Authority - ISO 9000 Certification for documentation and training.
Years: 1987 to 1991 Employer: Indian Institute of Technology Bombay, Powai, Mumbai, Maharashtra 400076 Title: Project Engineer Department: Metallurgical Engineering & Materials Science Responsibilities: Worked on the PMB-DST and CSIR projects to carry out forefront research and develop high-Tc ceramic superconductors.
* Synthesis, scale-up, shape forming, and characterization studies on dense high-Tc YBa2Cu3O7-d (1-2-3) superconducting ceramics.
* Directional solidification of high-Tc 1-2-3 ceramics using quench melt growth (QMG), and melt textured growth (MTG) techniques for improving critical current density (Jc).
* Developed 1-2-3 and BaCuO2 sputtering targets for superconducting thin film applications using laser ablation and RF magnetron sputtering techniques.

Worked on the DST project to carry out research and develop high creep resistant aluminum powder metallurgy alloys by rapid solidification processing.
* Developed and characterized novel creep-resistant rapidly solidified Al-6wt% Fe-6wt% Ni alloys using melt spinning technique.
* Developed creep-resistant Al-Fe-Ni alloys by mechanical alloying using attritor milling and high-energy ball milling techniques and compared with conventional Al alloys.
Years: 1984 to 1985 Employer: Indian Institute of Technology Bombay, Powai, Mumbai, Maharashtra 400076 Title: Metallurgical Engineer - R&D Department: Responsibilities: Carried out research and development projects on the hard-metals/cemented carbides for metal cutting, metal forming, mining tools, wear parts and hard facing electrodes.
* Designed a 3-zone reduction furnace by increasing the hot zone length and modifying insulation materials from sillimanite bricks and vermiculite flakes to kaolinite fiber wool. Optimized the reduction process for commercial production of fine, medium, coarse and super coarse grades of tungsten powder from tungsten trioxide for manufacturing hard metal/cemented carbides. The important results obtained are listed below: Reduced the number of reduction furnaces from existing 24 single-zone type to only 6 of the new 3-zone type furnaces resulting in huge cost savings. Reduced the floor space by >50% resulting in huge cost savings. Improved the productivity and yield by 400%. Reduced the thermal energy loss by ~150% leading to substantial savings
* Developed hard-facing electrodes with improved density, hardness, wear resistance and corrosion resistance by reverse engineering of competitor products, and metal cutting inserts and complex wear resistant parts by hot isostatic pressing (HIP).
* Provided technical support for the heat treatment of steel shanks for the metal cutting, metal forming and mining tools. Expert on heat treatment processes and mechanisms and troubleshot any heat treatment problems at various sub-contractors/vendors.
* Developed novel TiC, TiN, TiCN, TiAlN, Si3N4 and Al2O3 coated cemented carbide tools using physical and chemical vapour deposition techniques (PVD/CVD) on WC–6wt%Co hard metal inserts for metal cutting applications.

Career Accomplishments

Associations / Societies
Life Member, Powder Metallurgy Association of India. Member, Indian Ceramic Society. Member, Editorial Advisory Board, Cement Abstracts. Member, Library Advisory Committee, ACC-RCD. Member, Center for Dielectric Studies Consortium, Pennsylvania State University. Member, American Ceramic Society.
Publications and Patents Summary
Expert has 4 patent applications and several published papers

Additional Experience

Training / Seminars
* Teaching Associate for Graduate students, High Power Energy Storage, Pennsylvania State University, 1999-2000.
* Co-Instructor for Graduate students, Electronic Property Characterization of Materials & Capacitors, Pennsylvania State University, 2000-2001.
* High-Cap Tester Development presentations to muRata, AVX Corporation and Kemet Electronics.
* Advanced Termination presentations to many customers in Japan, Taiwan, USA, UK and Austria.
* Practical Data Analysis Seminar, Thermo (2005)
* Practical Process Improvement Training/Sensor Manufacturing Process Improvement, Thermo (2006)
* Root Cause Analysis & Failure Investigation Seminar (ASQ), Thermo (2006)
* Design for Manufacturability Workshop (WPI), Thermo (2006)
* Engineering Change Order Process & Procedures Training, Thermo (2006)
* Understanding Change and Change Management Seminar, Thermo (2008, 2011)
* Lean Enterprise Seminar on Lean Manufacturing, 5S, Value Stream Mapping, Standard Work and
Kaizen, Thermo (2009, 2010)
* Practical Process Improvement Seminar on the 8-Step Methodology, Thermo (2009)
Vendor Selection
Worked with Supplier/Vendor Location and Selection while working at Electro Scientific Industries, Escondido, CA 92029 & Portland, OR 97229, USA, Thermo Fisher Scientific (Thermo Electron Corporation), Franklin, MA 02038, USA and ACC Limited, Research & Consultancy Directorate, Thane (West) - 400 604, India.
Presently, working as a Sales and Marketing Representative for Vinayak Techno Ceramics in USA.
Marketing Experience
Materials Technology, Powder Metallurgy, Advanced Ceramics, Electronic & Structural Ceramics, Process & Product Development, R&D, Lean Manufacturing. Six Sigma
Other Relevant Experience
Research & Development, Product & Process Development, Process Control & Optimization, Advanced Materials Processing, Materials Technology & Characterization, R&D/Operations/Project Management, Process Metallurgy, Intellectual Property / Business Development, Marketing

Fields of Expertise

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