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Development
Engineer, 04545
Industry:
Extrusion- Films, Chemicals
Resides:
Georgia
Salary:
Open
Relocate:
Yes
On
the Market:
RECRUIT
WORK
EXPERIENCE:
1999 2002
Senior Development Engineer
Converter Films,Performance
Films Division
(Company)
Corporation MA and GA
Provide corporate film application feasibility and product/process development
for National and Regional converting accounts. Designed films up
to seven layers.
Major National accounts are Printpack and Sonoco, while major Regional
accounts include Bryce Corporation, Plassein and Interstate Packaging.
Have worked closely with Printpack and Sonoco to significantly increase
development projects. Sonoco business increased from ~$6MM to >$13MM
over this time.
Developed film that allowed major snack food manufacturer to increase
line speed by 34% with less than a 10% material cost increase.
Developed coex film for frozen food application that allowed structure
to be reduced from a two pass lamination (with a mono film sealant) to
a single pass lamination while also reducing overall cost of sealant web
Use experimental design/DOE/Six Sigma techniques in designing new products
and modifying existing products/processes, Black Belt Qualified.
Use knowledge of polymers and additives to optimize design of film structures.
In-house specialist on polymer stabilization.
Comfortable working with equipment from laboratory bench scale up to full
scale commercial.
Have experience formulating and processing of a number of different polymers,
i.e. PET, Nylon, PVC, PS, PP, PE, metallocenes, PU, PC, EVOH, and PPO.
1994 1999
Lead Polyolefins
Applications/Processing
Technologist
GE Specialty Chemicals
Parkersburg, WV
Carried out applications and polymer processing development activities
with proprietary processing stabilizers.
Determined feasibility of applications from a formulation and processing
prospective.
Provided processing support to customers on a global basis.
Utilized and developed various laboratory characterization techniques,
including statistical methods and DOE, to provide feedback to research,
quality, and manufacturing on performance and processability of current
and new additives.
Acted as a resource to GESC, GE, and outside customers on processing,
particularly in film, sheet, and fibers.
Optimized an internal test method to accurately predict the tendency of
a given stabilizer formulation to screen pack plug, reducing test time
from >16 hours to 6 hours.
Developed an internal test that simulated the tendency of a given formulation
to produce unacceptable die lip buildup. Previously no test existed.
Test presented to industry at ANTEC 1999.
Wrote programming for data acquisition system to collect processing data
from laboratory extruders and other equipment.
Had responsibility for monitoring departmental indirect spending.
Monitoring produced savings of 9.8% (versus a goal of 10%) in 1996 and
42.8% (versus a goal of 10%) for 1997. Total indirect savings was
over $680,000.
Responsible for daily upkeep of departmental LAN system and all desktop
computers.
Traveled globally to assist customers and their customers on processing.
Completed Greenbelt Six Sigma and DFSS training and 2 different Blackbelt
projects, Blackbelt qualified.
Completed classes in advanced DOE and computer analysis of designs.
Trained in loss analysis techniques.
1993 1994
Materials Development
Engineer
Coloplast Corporation
Marietta, GA
Provided total development/process/production responsibility for in-house
film production for outer covering of breast prosthesis.
Specified all equipment necessary for co-extruded film production.
Developed concept and designed equipment to enhance the film structure
which resulted in an annual savings of $500,000 in returned products and
quality rejects.
Developed cost analysis spreadsheet, which allowed sales to determine
accurate pricing in relationship to manufacturing costs.
Member of a team which developed materials, processes, and equipment necessary
to produce a custom breast prosthesis.
1990 1992
Extrusion, Technical,
Quality Control, Safety, Environmental Manager
Handgards, Inc. El Paso, TX
Managed plants extrusion, technical, and quality control departments,
including 25 direct reports.
Responsible for all capital engineering projects from procurement
to installation.
Modified process parameters to optimize productivity and changeover
from solvent based to water based inks.
Scheduled extrusion lines based on order load.
Responsible for all plant environmental and safety compliance
with governmental rules and regulations.
Performed all plant process engineering work in extrusion department.
1988 1990 Staff Plastics Process Engineer RUST International Corporation
Birmingham, AL
Determined clients requirements and designed processes and control
concepts.
Developed design criteria, flowsheets, P&Ids, specifications,
equipment lists, and scope-of-work statements for assigned projects.
Evaluated bids, negotiated with suppliers in procuring equipment,
and followed designs through detailed engineering phases.
Served as a consultant in specialized polymer processing areas.
Lead Process Engineer on the GE Plastics Structured Products
polycarbonate sheet extrusion expansion in Burkville, Alabama.
Lead Staff Engineer for the grassroots design, construction,
and startup of the Epsilon Products Unipol Polypropylene resin plant.
In this function supervised approximately 35 engineers.
1988 Senior Engineer - SPC Facilitator Hercules Incorporated Covington,
VA
Implemented complete SPC program in this blown BOPP film extrusion
facility.
Trained all operators and technicians in the hands-on aspects
of SPC.
Provided support for the computer systems group in managing the
programs for the SPC program.
1986 1988 Senior Plastics Process Engineer Packaging Corporation of
America Corporate Technical Center Skokie, IL (process work at Wheeling,
IL plant)
Spent 50% of time performing process analysis and plastics development
work at corporate research lab.
Balance of time was spent performing process engineering and
manufacturing supervision for CPET sheet extrusion and thermoforming operation
at Ekco Products plant site.
Responsible for installation and start-up of CPET extrusion/co-extrusion
sheet line.
Involved in installation and start-up of a Lyle Industries two-stage
thermoformer.
Performed process trials on the thermoformer, which allowed the
cycle time to be lowered from 12 to 6 seconds, thus increasing productivity
by 50%.
Wrote the SOPs and Operating manuals for the materials handling
and extrusion systems.
Chaired committee, which developed in-house production standards
for extruder sheet and formed parts.
Developed formulations which increased the temperature range
that formed parts could be used from 40°F - 350°F to -20°F - 410°F.
1983 1986 Production Supervisor Allied-Signal Specialty Films Division
Pottsville, PA
Supervised all operating personnel, purchased raw materials,
scheduling of line, calculation of all yields, and general maintenance
for the flat cast biaxial oriented PVC shrink film line.
Technical process engineer for the mono-axial oriented nylon
film product line, cast nylon film lines, and blown double-bubble PVC
shrink film lines.
Programmed plants Hewlett-Packard computer for daily follow-up
of individual extrusion line and departmental productivity.
Supervised approximately 35 people.
1980 1982 Technical Process Engineer E. I. DuPont de Nemours Polymer
Products Division, Mylar PET Film Florence, SC
Responsible for daily process trouble-shooting and process/project
development for Mylar PET film line.
Developed process parameters for the production of flatness critical
film for X-ray intensifier screens,
Responsible for production of magnetic substrate film for computer
floppy disks. Only vendor to qualify for supplier to new Verbatim plant
in Ireland.
Started-up in-line coating unit using microwaves to dry the film.
Also assisted in trouble-shooting in the continuous polymerization
area.
EDUCATION: 1980 B. S. - Chemical Engineering University of South Carolina
Columbia, South Carolina
PUBLICATIONS:- Information available upon request
INDUSTRY
ASSOCIATIONS: Member SPE Member, Advisory Council for Paulson Training
Programs, Film/Sheet Extrusion and Converting
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