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 Expert  720833

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

Available for your Consulting and Expert Witness Needs

Wisconsin (WI)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise:

Listed with other top experts in: 

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.

continuous quality improvement


quality control


quality improvement


Taguchi method


Taguchi method experimental design

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.



statistical method

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.

design of experiments

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.

new product development

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.

ISO 9002

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.

Weibull density function

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.

brazing alloy


ultrasonic soldering


vacuum brazing


aluminum brazing

Show Secondary and Basic Areas of Expertise
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;  and Gary, Indiana.

Year   Degree   Subject   Institution   Honors
1972   PhD   Metallurgy   Iowa State University  
1966   MS   Metallurgy   Iowa State University  
1964   BS   Physics   University of Massachusetts - Amherst   Hasbrouck Award, 1963

Work History:
Years   Employer   Department   Title   Responsibilities

1987 to


(Undisclosed Consulting Company)



Principal Scientist


Guide resolution of client product and productivty issues. Design and implement client Quality/Operations systems. Analyze client product data and improve product quality & value.

1987 to 1998


Milwaukee School Of Engineering





Instructed undergraduates in metallurgy, advanced statistics, thermodynamics, and other subjects as needed.

1980 to 1987


Allen-Bradley Company


Metallurgy and Physical Test Lab


Manager, Principal Scientist


Directed materials lab and resolved materials issues.

Developed corporate & employee capability in Taguchi Method(tm) statistical analyses.

1979 to 1980


Modine Manufacturing Company



Chief Engineer


Directed development of new heat exchangers, most notably, the Beta-Weld Radiator.

1974 to 1979


Aluminum Company of America



Senior Engineer


Developed new brazing alloys. Served as customer liason for brazing. Refined vacuum brazing process capability. Reduced alloy proliferation and costs.

1972 to 1974


Carnegie-Mellon University



Research Fellow


Developed software for thermodyanmic/phase diagram calculations. Directed the production of a one-hour, color film for instuctional purposes.

Career Accomplishments:

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) since 1965.

He has also been a member of the American Society for Quality (ASQ) since 1988.


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 since 1988.

Professional Appointments

ASQ - Racine-Kenosha-Walworth Chapter Treasurer, 1998-2000 Publicity Chair, 1999-Date


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, including the book, Metallurgy Fundamentals, co-written with Dan Brandt.

Selected Publications and Publishers  
 - The UMAP Journal  
 - Project Management Journal  

Consulting Services:
Selected Consulting Examples:
  • 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.
Recent Client Requests:
  • Taguchi method expert for consulting on sputtering of hard drive media.
  • Aluminum brazing expert for consulting on Aluminum Dip Brazing, Vacuum Brazing and Heat Treatment.
  • Weibull analysis expert in Wisconsin for consulting on field failure prediction.
Click the green button above to contact Expert for a free initial screening call regarding your expert consulting needs.  Expert is available for consulting to corporate, legal and government clients.  Remember, your initial screening call to speak with Expert is free.

Expert Witness:
Expert Witness Experience Summary:
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.

Click the green button above to contact Expert for a free initial screening call regarding expert testimony, litigation consulting and support, forensic services, or any related expert witness services.  A few litigation needs include product liability, personal injury, economic loss, intellectual property (patent, trademark, trade secret, copyright), and insurance matters.  Remember, your initial screening call to speak with Expert is free.

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

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

Market Research:
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.

Click the green button above to contact Expert for a free initial screening call regarding your marketing research, industry research, and company research needs.  For research needs involving multiple experts or secondary research, a Research Director can be assigned to coordinate the work into a custom report for you as a potentially quicker and more cost effective alternative to doing this work yourself or hiring a boutique consultancy.  Remember, your initial screening call to speak with Expert is free.

Additional Skills and Services:

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.

Other Skills and Services

Wisconsin Forward Award Examiner, 1998-date ("Baby Baldrige").

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


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