Expert Details

Expert in Polyurethane Foam Formulations/Processes,Automotive Acoustical Parts,Fibers/Plastic Recycling

Expert ID: 725081 Nevada, USA

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Expert has leveraged his graduate/post-graduate academic training in organic chemistry and his doctoral dissertation work with organo-metallic compounds to an in-depth knowledge of, and expertise in:
-chemical intermediates
-fine chemicals
-fine chemical intermediates

He has specifically applied this theoretical and practical hands-on expertise to chemical product development, formulating, marketing and commercialization of a comprehensive portfolio of diisocyanates and polyurethane formulations, a family of automotive chemicals and acoustical fibrous materials used by the automotive industry for seating, interior trim, acoustical noise abatement and buzz, squeak and rattle applications.
He was highly instrumental in developing and introducing automotive acoustical polyurethane foams for ICI Polyurethanes into the North American market. This range of products became the market leader within five years of introduction.
Other chemical and system urethane formulations were also successfully commercialized, under his technical and marketing direction, as Division Marketing Manager, for furniture and adhesive-related applications.
Within 8 years of its creation in 1987, ICI Polyurethanes' Sterling Heights division, which was in charge of developing and marketing specialty diisocyanate products and formulations saw its sales reach $97 million in 1995.

Expert's technical and technology executive positions at automotive component and material suppliers, such as Perstorp Components, Collins & Aikman Corporation (C&A), Lear Corporation and International Automotive Components North America, have focused on automotive textiles.
He has been highly instrumental in developing and introducing to the market innovative products and processes, as demonstrated by two published US patents (2006 and 2007) and one pending US patent application (2008); new developed technology was recognized as the key driver in increasing in 2006 new business backlog by $50 million for the 2008-2011 model year cycle.
He is also responsible for creating in 2000 a product brand name (SonoTec) for Lear Corporation's range of acoustical automotive textile products and successfully nurturing it to a leadership position against its market competitors. Expert has managed and directed multi-national teams of material and acoustical engineers (up to 40 people) working with organic compounds, nonwoven fabrics and nonwoven polyester mats. These activities also encompassed product cost reduction and product and performance improvement projects through plastic product development, polymer selection for chemical compatibility and product formulation.
These cost reduction programs saved Lear Corporation $2.1 million in 2005 and $1.6 million in 2006.
He has also an extensive experience in the management of lower Tier material suppliers to optimize the value of products he offered to his customers.
In addition to his leadership in acoustical product development, Expert was given the responsibility at Perstorp Components and C&A, to run their major acoustical testing facility (including a 4-wheel chassis dynanometer) as a profit center. Besides conducting evaluation of the companies' own products, he was able to generate outside customers' sales of ~$1 million on a yearly basis for 3 years, thereby reducing overall laboratory's burden costs.
In his various technical positions, Expert managed development groups of up to 40 people located in different facilities, and budgets of up to $5 million/year.

While Expert has demonstrated a wide range of technical skills and know-how that have been successfully applied to polymer selection, new product assessment and material development in the chemical and automotive industries, his 30 years of industrial experience in the plastics industry have also included marketing and business development activities on a global basis. As such, he has been deeply involved in product management, cost analysis, new business quoting, crafting and implementation of marketing and business plans. These activities have included the analysis of market trends, conducting new product market surveys, new technology business value measurement and polymer marketing. More specifically, he and his group supported in 2007 flooring and acoustics quotes for 5 major OEM projects worth $100 million over 3 years.
Total value of business supported by Expert and his teams was generally in the $400-500 million/year range.
Expert's dual set of business/commercial and technical skills have proved particularly useful and advantageous to his various employers; they should also be a major asset to his future clients in providing solutions to the challenges they are faced with.

Expert has leveraged his organic chemistry training and knowledge in acquiring an in-depth knowledge of isocyanate (specifically diphenylmethane-4,4'-diisocyanate and derivatives such as isocyanurates), polyurethane chemistry and associated manufacturing processes, such as foam-in-place used in automotive seating. He has applied his expertise in polymeric materials and hands-on experience with automotive parts and components to thoroughly investigate and develop formulations/processes for the recycling of post consumer and post industrial automotive streams (plastics, polyurethanes).

Provided the client (a material supplier) with an in-depth analysis of the North American Automotive Acoustical Fiber Markets and Technologies (floor systems, dash insulators, trunk trim), North American Acoustical Fiber Products (requirements, opportunities, suppliers, pricing) and a projection of IAC North America's strategy regarding in-sourcing of acoustical raw materials.Report for a material supplier summarizing 2007-2011 North American floor system and dash insulator market sourcing, by OEM (Original Equipment Manufacturer), by vehicle platform, by supplier and by product technology.Full report for a chemical material supplier analyzing the competitive environment and growth prospects for acoustical polyurethane foams in the North American automotive interior trim market.White paper for an industrial customer analyzing technical and financial requirements for setting up an in-house rigid polyol formulation blending operation. Consulted for a client on the market for sound and vibration testing solutions (e.g., microphones, accelerometers, DAQs, analysis software); more specifically market's long term outlook and competitive positioning of current sound and vibration testing solution vendors.

Expert may consult nationally and internationally, and is also local to the following cities: Las Vegas, Nevada - Henderson, Nevada - North Las Vegas, Nevada - San Bernardino, California - Ontario, California - Fontana, California - Rancho Cucamonga, California - Upland, California - Chino, California - Victorville, California

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Year Degree Subject Institution
Year: 1974 Degree: PhD Subject: Organic Chemistry Institution: Purdue University
Year: 1971 Degree: MS/BS Subject: Chemistry/Chemical Engineering Institution: Ecole Nationale Superieure de Chimie de Paris (France)
Year: 2011 Degree: Paralegal Certificate Subject: Law Institution: Oakland University, Rochester, Michigan

Work History

Years Employer Title Department Responsibilities
Years: 2010 to Present Employer: Undisclosed Title: VP Technology Department: Responsibilities: He is responsible for development and implementation of innovative processes to recycle automotive interior trim waste materials into useful industrial products
Years: 2008 to Present Employer: Undisclosed Title: Principal Department: Responsibilities: As owner and principal of Automotive Interior Consulting, Expert focuses on providing technical and marketing services to domestic and overseas organizations involved in developing, producing and recycling a wide range of interior trim parts for the global furniture and transportation industries, specifically components based on polyurethane and fiber-based materials. In the automotive sector, he specializes on a very diverse range of value-added polymeric materials and composite constructions that improve vehicles' interior comfort and quietness. He is placing particular emphasis on the optimization of cost, weight and NVH (Noise, Vibration, Harshness) performance throughout the entire acoustical development process (benchmarking, product development, prototyping, performance validation and cost estimating).
Years: 2007 to 2007 Employer: International Automotive Components North America Title: Director, Advanced Sales & Engineering, Flooring & Acoustics Department: Advanced Sales & Engineering Responsibilities: -He managed RD&E for all flooring and acoustics’ material/product/process development activities.
-He directed 20 engineers/technicians located in Dearborn, MI headquarters and Carlisle, PA production facility, with total annual budget of $5.5 million.
-He was responsible for internal acoustical product development and customer-specific NVH vehicle optimization projects (cost/weight/performance) that met customer technical targets.
-He supported new business quoting process (5 major projects) worth $100 million over 3 years.
-He developed group’s technical strategies; implemented development programs meeting business objectives, including Intellectual Property issues with outside counsel; holder of 2 US patents.
Years: 2001 to 2007 Employer: Lear Corporation Title: Director, Flooring & Acoustics Products Department: Flooring & Acoustics Business Group Responsibilities: -He developed and implemented Lear’s North American short/long-term product/marketing/business strategies
-He led F&A product costing, generated business cases, devised pricing strategies by working with division finance staff to analyze and optimize Lear’s value chain.
-He directed group’s internal and suppliers’ continuous cost reduction programs (CTO) yielding savings of $2.1 million and $1.6 million, in 2005 and 2006, respectively.
-He managed cross-functional platform teams responsible for new OEM programs via new parts/systems business quotes, customer technical/business reviews, and market tests; contributed in 2006 to a $50 million business backlog increase for 2008-2011 model years.
-In liaison with Corporate Purchasing, he led Product Group’s technical activities, including program management and development of strategic Tier 2/Tier 3 partners; directly managed 5 professionals with budget of $1.8 million.
-He formulated and implemented product group’s internal communication strategies.
Years: 1999 to 2000 Employer: Lear Corporation Title: Director Department: Corporate NVH Strategy and Applications Engineering Responsibilities: -He crafted Lear’s global NVH/soft acoustical trim strategy to support $400 Million F&A business
-He chaired Lear’s cross-functional NVH Strategy Team, accountable for new business development targets, technical innovation, and partnerships with Tier 2/Tier 3 suppliers.
-He managed market introduction of Lear’s new SonoTec brand of light weight NVH technologies.
-He created in October 1999 and led corporate-wide NVH Engineering team (10 engineers) to improve responsiveness to customers’ requirements and re-establish Lear as a market leader.
Years: 1997 to 1999 Employer: Collins & Aikman Corporation Title: VP Technology Department: Carpet and Acoustics Division Responsibilities: -He planned, directed and managed carpet and acoustics technical activities: new product/ materials engineering, acoustical/trim systems development with team of 21 engineers
-He was responsible for operating division’s NVH Technical Center and materials testing function.
-Initiated and managed all Tier 2/3 material suppliers’ R&D/continuous improvement projects.
-He promoted to global customers C&A’s overall technical capabilities in interior acoustical trim.
-He oversaw an operating budget of $5 million/year and impacted $800 million in global sales.
-He coordinated international technology development via Technology Steering Committee.
-He consolidated, rationalized and strengthened Division’s technical organization after December 1996 C&A’s purchase of Perstorp Components and J.P.Stevens Automotive.
Years: 1995 to 1996 Employer: Perstorp AB Title: VP Technical Services Department: Responsibilities: -He formulated and implemented North American technical strategy.
-He streamlined and centralized former plant-based engineering and technical functions into cohesive, multi-disciplinary team (40 technicians and engineering professionals).
-He guided corporate continuous improvement team to $9.7 million annualized cost savings.
Years: 1993 to 1995 Employer: Huntsman Polyurethanes (formerly ICI Polyurethanes) Title: Division Marketing Manager Department: Sterling Heights Division Responsibilities: -He conceived and executed Americas’ Strategic and Marketing/Communication plans for Automotive Interiors, Furniture, Footwear and CASE segments via 4 marketing professionals.
-He contributed to 12.8% and 13.9% sales increases in 1993 and 1994 to $85.4 and $97.3 million.
-He developed and implemented North American Automotive Strategic and Marketing/Communication plans.
-He delivered 117% and 13.5% automotive sales increases in 1991 and 1992 to $43.7 and $49.6 million.

International Experience

Years Country / Region Summary
Years: 1980 to 1983 Country / Region: United Kingdom/Europe Summary: -Marketed throughout Western Europe Rogers Corporation's portfolio of value-added polymeric engineered products (RTV silicone rolls, PTFE-coated steel rolls, polyurethane foam rolls and belts)to European reprographics equipment producers (Rank-Xerox, Pelikan, Deutsche Cannon and Minolta, Oce, Gestetner, Olivetti...)
Years: 1984 to 1984 Country / Region: Belgium/Europe Summary: -During 9-month stay at ICI Polyurethanes world headquarters in Brussels, was tasked to become intimately familiar and fluent with proprietary polyurethane flexible foam products, while also training two technicians
-Objective was to insure orderly transfer of European formulation technology/expertise and production processes to US-based operations (Delaware and Louisiana) in order to replace expensive European-produced chemicals

Career Accomplishments

Associations / Societies
-SPE (Society of Plastics engineers)
-SAE (Society of Automotive Engineers)
-Past member of ACS (American Chemical Society)
Awards / Recognition
-Member of Sigma XI (Honors Chemical Society)
-Graduate Assistant on a research grant supported by the National Institutes of Health
Publications and Patents Summary
-6 academic papers in the field of chemistry partially covering topic of doctoral dissertation
-Holder of 2 US patents
-Applied for 3 US patents (pending)

Additional Experience

Expert Witness Experience
Participated in auditing automotive manufacturing operations to identify and qualify proprietary or trade secrets processes.
Consulted with plaintiffs' attorneys in recommending technical arguments to secure trade secret violation judgments.
Was part of hearings with attorneys designed to finalize trial strategy regarding alleged misappropriation of know-how and automotive parts manufacturing company's trade secrets by former employees.
Training / Seminars
Conceived and presented seminars on applications of polyurethane flexible foams in the automotive and furniture industries.
Developed and delivered training courses on formulating and testing performance of a wide range of polymeric materials for acoustical applications.
Developed and presented similar courses on construction and behavior of woven and non-woven fabrics for carpeting and acoustical applications in the automotive industry.
Was recognized as the acoustical materials expert within the companies he was involved with.
Vendor Selection
Led numerous product development projects in the automotive interior trim and acoustical industry with the support of Tier 2/3 material suppliers, including the co-development of proprietary technologies (product constructions and/or processes).
Was responsible for guiding, directing and managing suppliers' entire technical efforts during the new product development process.
Worked with the purchasing community to ensure that suppliers-related development programs met commercially-driven cost hurdles.
Coordinated new products scale-up and plant evaluation with suppliers to ensure manufacturability.
Marketing Experience
Qualifications summarized below apply to the specialty chemicals industry and the automotive trim industry where Expert operated during his career:

In conjunction with direct involvement in technical development activities, was also responsible to monitor the business segment's competitive environment - both from a supplier and customer standpoint.
Various positions in marketing and business development required frequent and in-depth contacts with competitors (carefully, in this case), customers and suppliers in order to collect the type of market information required to develop, as accurately as possible, the group's marketing and business plans (Examples: overall market growth prospects, customers and suppliers competitive environments, evolution of technologies on a global basis, emergence of low cost overseas suppliers, evolution of market prices for commodity and specialty materials, logistics-related cost factors, robotization and reduction of manufacturing cycle times to reduce overall production costs, new lighter materials that provide value-added performances...)
Other Relevant Experience
International technical experience gained through working for companies operating on a global basis.
Fluent in French and working knowledge of German.
Proven ability to launch, lead and coach cross-functional, multi-cultural and multi-lingual development and business teams.
Skilled at building and maintaining relationships with mid-level and senior technical and purchasing personnel.

Language Skills

Language Proficiency
French Mother tongue
German Working knowledge that could be substantially improved with refreshing course

Fields of Expertise

applied organic chemistry, automotive chemical, commercialization, diisocyanate, fine chemical, fine chemical intermediate, chemical intermediate, buzz, squeak, and rattle, automotive industry, chemical product development, fine chemical marketing, chemical marketing, organometallic compound, automotive textile, automotive component, nonwoven fabric, nonwoven polyester mat, organic compound, performance, plastic product development, polymer compatibility, polymer selection for chemical compatibility, product, product cost reduction, automotive plastic, product formulation, product improvement, automotive material, new product development management, market trend, marketing, material product development, new product assessment, new product development, new product market survey, new technology business value measurement, plastics industry, polymer marketing, polymer selection, product management, automotive recycling, diphenylmethane-4,4'-diisocyanate, foam-in-place, isocyanate, isocyanate resin, isocyanurate, polymer, polymer recycling, polyurethane, polyurethane recycling, post consumer plastic recycling, post consumer recycling, carpet surface, business analysis, industry standard, customer segmentation, polyethylene terephthalate recycling, composite fiber, automotive transportation, stage gate process, polymer processing, overall cycle time, plastic handling, elastomer blend, thermoplastic material selection, polymer fatigue, plastic service-life prediction, plastic material test procedure, Society of the Plastics Industry, aryl compound, plastic manufacturing, depolymerization, joint venture, polymer degradation, automotive design, European marketing, fine organic synthesis, elastomer selection for chemical compatibility, nonwoven fabric processing, elastomer selection, crumb rubber, needlepunch, product reliability improvement, fireproof nonwoven fabric, nonwoven fabric web, product testing, new chemical process operations, nonwoven fabric surface property, rapid product development, nonwoven fabric technology, microfiber, product design variation reduction, design for cost, product manufacturing, engineering plastic, product delivery process, corporate strategic planning, product development cycle time, scrap plastic, new product design, integrated product development, automobile safety system, device product development, nonwoven fabric manufacturing, design for manufacturability, design for recyclability, thermoset polymer recycling, high-performance polymer, meltblowing, product design, plastic material, polymer testing, high-temperature plastic, automobile, motor vehicle, legal patenting, innovation, nonwoven fiber processing, process technology, copolymer, monomer, aromatic compound, chemical compound, plastics safety, planning, material substitution process, industrial chemical, homopolymer, felt, cellular plastic, automotive engineering, automotive composite, automotive adhesive

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