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 Expert  723312

Expert in Product and Process Development, Design of Experiments, Root Cause Analysis, Program Management

Available for your Consulting and Expert Witness Needs

Minnesota (MN)
Education Work History Career AccomplishmentsPublicationsConsulting Services Expert Witness Market Research

Summary of Expertise:

Listed with other top experts in: 

He began developing and seeing results from his Design Of Experiments techniques at the General Motors Research Labs in 1986. He has refined and tested them in various environments, including automotive, aerospace instrumentation, armament technology and medical products in roles ranging from R&D, to design and production. His unique insight into how Design Of Experiments is best used has saved project schedule (months) and money ($400k on average) while solving problems in all of these industries. He also has the ability to gain insight in data that is previously considered "useless".

He has been grooming a new generation of experts in a university setting since 1996. This involves a semester long, graduate level course in Design of Experiments.

He partners with a company's innovative thinkers for strategic testing. This helps to design and improve products and processes for focus, robustness and optimization. For growing, technically based companies, this has saved money, reduced development time by months and resolved competing requirements. The implementation track record of over 300 projects averaging $40k of benefit each speaks to the results obtained. Tools covered include full and fractional factorials, central composite, Box-Behnken, Taguchi, D-Optimal, mixtures and other advanced tools. Analysis software includes Minitab, Design-Expert and JMP.


design of experiments


statistical design of experiments


Taguchi method experimental design


response surface methodology


central composite design


Taguchi method


statistical computer software

Process optimization requires several considerations: process understanding, determination of desired standarized working levels and practical considerations to maximize yields yet reduce variability. It is also important to handle uncontrollable input variations. He has demonstrated this ability to see beyond basic application of Design Of Experiments in his work with companies. The resulting solutions have been maintained for years after initial introduction, thus eliminating issues that had existed for a long time.

process optimization


process design variation reduction


manufacturing process optimization

Good product design leads to good process implementation. He has led design projects with cost and manufacturability targets ranging from $10,000 systems to $1,000,000 systems. The end products require high reliability, critical operation and profitable business results. Customer feedback has recognized the ability to see the design from the customer point of view. Obtaining understanding through simulations, modeling and Design of Experiments has provided supportable designs, reduced prototyping costs and getting to market quicker. This understanding leads to nominal settings and tolerance specifications which reduce product variation and deal with environmental noise.

product design


product design variation reduction


research and development

He has experience performing product testing for a wide range of customer expectations, including FDA Testing, was conducted for electrical properties, mechanical performance and user interface. Test objectives ranged from Research and Development projects for proof of concept, design for new product releases, laboratory for pilot plant start up, manufacturing process capability, product and process optimization, and for validation of manufacturing processes. Understanding of requirements, design intent and engineering principles has made for efficient yet effective test strategy development.

product testing


optimization experiment

Experimentation and design of products and processes are dependant on adequate measurement systems. This area is related to the core Expert focus of Design of Experiments. This component is part of an industrial training program that the Expert teaches and applies.

gage R&R test procedure

Using engineering principles and empirically developed equations through Design of Experiments naturally leads to the use of Monte Carlo methods for sensitivity analysis and decision making. Expert has developed and executed projects using a mix of the above techniques to resolve challenging situations.

Monte Carlo method

After developing products and processes, a related area is to ensure long term process capability and process control. Expert has experience applying these tools and teaching them within applied industrial courses. Division wide implementation projects have provided the Expert a scope of issues and the key needs for success.

process capability study


statistical process control

FMEA is a tool that can highlight the need for Design of Experiments. The medical industry increasingly uses FMEA to assess risk. Expert has experience applying FMEA to design and to processes in several industries. He also teaches an FMEA component in an industrial training program.

failure modes and effects analysis


process failure modes and effects analysis

Expert has experience applying QFD in high visibility situations. This has gone beyond the basic "House of Quality" approach. It includes concept selection and breakthrough techniques. Highlighted areas from the QFD effort often identify opportunities for use of Design of Experiments. At a minimum, QFD can focus and prioritize resources in a project plan and develop a strategic product development road map.

quality function deployment

Expert has knowledge and experience with project management tools for product, process and software development efforts. Scale has included up to $30M projects. He also has experience with estimating costs for development efforts. This has included parametric methods, bottoms up and similarity. Working with company experts, this skill allows development projects to have a reasonable estimate for completion. This includes assessment and inclusion of the risk potential into cost and schedule estimates. Expert has experience with contigency plans for projects in the execution phase. While Design of Experiments is one way to reduce cost and schedule, it is only one technique used. Other techniques include basic project strategy, people aspects to project management and early identification and removal of roadblocks. These techniques are taught within the university classroom setting and in industrial training as a part of running a successful Design of Experiments project.

cost estimation


engineering project management


project cost estimation


project management


project planning


risk management

Show Secondary and Basic Areas of Expertise
Expert may consult nationally and internationally, and is also local to the following cities: Minneapolis, Minnesota;  Saint Paul, Minnesota;  Rochester, Minnesota;  Burnsville, Minnesota;  Saint Cloud, Minnesota;  Eden Prairie, Minnesota;  Minnetonka, Minnesota;  and Eau Claire, Wisconsin.

Year   Degree   Subject   Institution   Honors
1988   BS   Mechanical Engineering   University of Minnesota, Minneapolis   Graduate with Honors

Work History:
Years   Employer   Department   Title   Responsibilities

2006 to







He provides training for companies in DOE, Statistics and Program Management. He supports project applications for client companies in those same areas, creating speed records for getting to market.

1996 to


(Undisclosed University)


Graduate Engineering


Adjunct Professor


He teaches a graduate student Design of Experiments course plus assists in a Clinical Study Design course for Medical Devices.

2002 to 2006






Project Manager


He was responsible for project management aspects for new product development projects in manufacturing. He was also responsible for DOE training development and support of internal projects.

2000 to 2002






Project Manager


He was responsible for project management aspects for battery development for new product development projects. He was also conducted DOE training and provided DOE project support.

1992 to 2000


United Defense



Project Manager


He was responsible for project management aspects for design and manufacture of new product development activities. He also developed internal DOE training and supported internal projects.

1988 to 1991





Design Engineer


He was responsible for design engineering and production support of products. He also had responsibility for new product development project management and using DOE in support of these roles.

1986 to 1987


General Motors



Scholar program


He was responsible for testing and design of manufacturing related systems. This included DOE on processes.

Career Accomplishments:

He is a member of ASQ.


He is a Professional Engineer registered in Minnesota.

Publications and Patents Summary

He has published over 15 papers and presentations related to testing and DOE. He has written 2 magazine articles on SPC and DOE. He has 3 hour long radio interviews on business and problem solving topics.

Consulting Services:
Selected Consulting Examples:
  • He resolved a manufacturing process issue which was risking the product development investment for a significant project. This resulted in operating in an unexpected area yet the capability of confident production and delivery of products.
  • He helped develop a testing strategy for a new product development project. Historically, the competing requirements could not be resolved cost effectively. In a short period of time, a scalable solution was found to meet the current needs as well as future needs.
  • He provided DOE training services to a company who was reluctant regarding the value of training in general. After the first DOE training class was completed, the VP of operations requested additional training courses to be conducted as soon as possible based on the benefits created for the company.
  • He provided DOE expertize to create a design solution for an implantable medical device that most thought was an impossible project. He further provided manufacturing process improvements so the production was of higher capability. Within all of this, he assisted the project manager to deal with the management aspects of the project - dealing with the executive team as well as with team members.
  • He has developed training for companies who want the secrets of how to apply tools, not just hear about general templates and techniques. This has resulted in practical training with use in actual work applications. It also provides usable reference materials when challenging situations crop up in the future.
Recent Client Requests:
  • Flow control expert for consulting on test optimization procedures.
  • Expert in Capability Study for Product Dimension Control - Food Manufacturing.
  • Expert in Pre Preg Material Selection.
  • Expert in software for consulting on design of experiments.
  • User interface expert for consulting on automotive user interaction evaluation.
  • Expert in DOE for consulting on training to a group of engineers and lab technicians.
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:
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
2003 to 2004   Ireland   He was the liason during development of a new product and then transfered the manufacturing of new product to this Ireland facility. This included in person visits.
1998 to 1998   England   He led the design and testing of a new product with a company in England. This included in person visits.
2008 to   Europe/ Asia   A variety of consulting projects have involved Expert with technology companies in Italy, Russia, Vietnam, Japan and China.

Market Research:
He has wide experience with the engineering aspects of bringing ideas to market. This includes identifying needs, dealing with changing customer requirements, optimizing the competing requirements and constraints, and ensuring satisfaction after delivery.

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:

He has developed and delivered 1 hour, 1/2 day, 1 day, 3 day, 5 day and 7 day training for DOE applications. Similarly he has developed and delivered a range of statistics course, more commonly called Decision Making with Data. He has also provided a variety of problem solving training sessions, including Innovation, Root Cause Analysis and Failure Modes and Effects Analysis.

Supplier and Vendor Location and Selection

He has knowledge of the available software used in DOE analysis and is also aware of the text book availability and quality. More generally, he is aware of many vendors for engineering applications.

Other Skills and Services

He is familiar with the patent process and requirements.


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