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 Expert  727745

Expert in cGMP Coatings, Adhesives, Die Cutting, Security Holograms, Printing, Operations Management Metrics and Strategy, and Materials


Available for your Consulting and Expert Witness Needs

Pennsylvania (PA)
USA
Education Work History Career Accomplishments Consulting Services Expert Witness Market Research

Summary of Expertise: Listed with other top experts in: 
Expert has worked in custom manufacturing – polymerization, mixing, coating and converting of cGMP adhesive and laminates - as a process engineering manager. In this role he lead operations and engineering on the corporate Business Strategy Team (BST) asserting direction for each division sales plan, budget, strategy, and quarterly goals; managed the outsourced manufacturing of all polymerization, mixing, coating, and converting of products to increase capacity, cash flow, reduce capital outlay, improve on time delivery, yield, maximize total value, and product margin; as well as assisted process engineers and operations associates to successfully develop and manufacture cGMP food grade oral dissolvable films, medical device, pharmaceutical transdermal drug delivery, industrial, electronic adhesive products, and silicone/ fluoropolymer release liners. He also completed stage gate product/process development projects increasing revenue by over $7MM and instilled accountability and discipline to product development and process improvement utilizing a stage gate development and statistical Six Sigma program. Expert has been involved with margin improvement programs. He has developed and commercialized adhesive products which required regulated clean controlled manufacturing environments as well as conductive transfer and repulpable adhesive products. He executed the factory acceptance, installation qualification, and startup of new cGMP extrusion slot die coating, mixing technology, and key products to for his firm's Limerick, Ireland (green field site). Expert's expertise includes fixed and adjustable lip slot die extrusion, reverse roll, gravure converted products, rotary die cutting and slitting technical service..

While at International Paper Company. he was a production manager and managed the thermoplastic and thermoset molded industrial plastics department.

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adhesive application machine

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adhesive application process

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adhesive applicator equipment

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adhesive compounding

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adhesive curing

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adhesive failure analysis

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adhesive manufacturing

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adhesive material film

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adhesive paper

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adhesive pump

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adhesive tape-coating material

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anaerobic adhesive

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anisotropic adhesive

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automotive adhesive

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clean room coating material

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clear coating material

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coated paper

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coated polymer film drying

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coated web

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coating applicator

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coating machinery

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coating material failure

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coating material specification

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coating system

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coating technology

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commercial coating

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electrically conductive adhesive

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electrically conductive coating

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electromagnetic interference conductive coating

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engraved-roll coating process

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flexographic coating process

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knife-over-roll coating process

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paperboard flexographic printing

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polymer thick-film ink

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pressure-sensitive adhesive

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rubber adhesive

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silicone adhesive

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skin adhesive tape

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solvent adhesive

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wood adhesive

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wood adhesive resin


Show Secondary and Basic Areas of Expertise
Localities:
Expert may consult nationally and internationally, and is also local to the following cities: Philadelphia, Pennsylvania;  Allentown, Pennsylvania;  Reading, Pennsylvania;  Bethlehem, Pennsylvania;  Lancaster, Pennsylvania;  Camden, New Jersey;  Vineland, New Jersey;  Wilmington, Delaware;  Baltimore, Maryland;  and Alexandria, Virginia.

Often requested
with this expert:

Web Coating Technology
Paper/ Plastic Web Processing/ Handling; Custom Converting...
Flexible Packaging Processes: Rotogravure Printing,...
Product Development and Marketing of Adhesives and...

Education:
Year   Degree   Subject   Institution  
1994   BS   Chemical Engineering   University of Maryland  

Work History:
Years   Employer   Department   Title   Responsibilities

2007 to

 

(Undisclosed)

 

Production Management

 

Director of Operations, Plant Technical Manager

 

Security printing, converting and liquid crystal coating -- brand protection, government high security and banknote applications.

Plant and Technical Manager (February 2007 – Present)

• Responsible for operations profit and losses including product quality, material yield, on time delivery and throughput optimizing operating profit.

• Empower and develop team members to create and achieve production goals, track process efficiencies and losses (KPI). • Quantified $3.1M in annualized margin improvement initiatives and accountability for actual product costs to drive Process Engineering priorities. >$1.5 million in actual material and labor savings YTD.

• Design and initiated a formal stage gate product development process with a cross functional team of R&D and Market facing groups in compliance with cGMP and ISO 9001. Production capacity and material planning is forecasted through this pipeline funnel.

• Achieve results through lean transformation using 5S, Quick Changeover, and Kaizen projects for optimum organization and quality throughput. Manufacturing cycles have been reduced < 50%, which actually reduced waste.

• Responsible for plant safety, process safety management (PSM) programs with 2009 overall TIR <0.5.

• Actively promote OpSec brand protection customers and government agencies on the benefits of OpSec technology, products and services.

• Use six sigma data analysis techniques to drive continuous improvement and reduced variation quality errors. This has reduced spoilage and material waste contributing to the large cost saving results.

1998 to 2007

 

Adhesives Research Inc.

 

Medical and Industrial

 

Process Engineering Manager

 

Adhesives Research Incorporated Glen Rock, PA (ISO 9001,cGMP FDA registered site) Custom manufacturing – polymerization, mixing, coating and converting of cGMP adhesive and laminates

Contract Manufacturing and Process Engineering Manager, (October 1998 – February 2007)

• Lead operations and engineering on the corporate Business Strategy Team (BST) asserting direction for each division sales plan, budget, strategy, and quarterly goals.

• Manage the outsourced manufacturing of all polymerization, mixing, coating, and converting of products to increase capacity, cash flow, reduce capital outlay, improve on time delivery, yield, maximize total value, and product margin.

• Empowered process engineers and operations associates to successfully develop and manufacture cGMP food grade oral dissolvable films, medical device, pharmaceutical transdermal drug delivery, industrial, electronic adhesive products, and silicone/ fluoropolymer release liners.

• Successfully completed stage gate product/process development projects increasing revenue by over $7MM. Instilled accountability and discipline to product development and process improvement utilizing a stage gate development and statistical Six Sigma program.

• Initiated and completed margin improvement programs resulting in sustained $1.3MM annualized savings.

• Developed and commercialized ARclearTM optically clear display adhesive products using regulated clean controlled manufacturing environments as well as ARcladTM conductive transfer and repulpable adhesive products.

• Executed the factory acceptance, installation qualification, and startup of new cGMP extrusion slot die coating, mixing technology, and key products to Adhesives Research, Limerick, Ireland (green field site).

• Solved manufacturing challenges involving fixed and adjustable lip slot die extrusion, reverse roll, gravure converted products.

• Communicated with customers to solve product and processing challenges including rotary die cutting and slitting technical service and potential new market development contributing to over $100 M in sales.

1994 to 1998

 

International Paper Inc.

 

Paper and Plastic Products

 

Production Manager

 

International Paper Company

Production Manager, Hampton, SC ISO 9002 Certified (June 1997 – September 1998) • Managed the thermoplastic and thermoset molded MicartaTM industrial plastics department. Directly responsible for the assembly, plastic molding, finishing and packaging operations.

• Empowered the team members to achieve aggressive production goals, track process efficiencies and losses.

• Responsible for the improving quality and customer service.

• Provided technical expertise to the bulk resin production, treating and molding of epoxy, phenol, silicone and melamine products.

Project Manager ARmored Protection (ARP) Paper Coatings: Responsible for design, startup, and optimization of the new coating operation. Developed new high performance specialty decorative plastic molded products.

• Managed the mixing preparation and new coating operation areas. Responsible for allocating new raw materials, chemical formulas, and coating specifications.

• Developed and optimized the resin chemical formulations. Statistically designed optimization experiments (DOE) to setup and optimize the coating process variables.

• Managed the trouble-cause-correction program: certified Kepner-Tregoe instructor. Find the true cause of problems with analytical troubleshooting and prevention. Process Engineer and Production Supervisor, Odenton, MD (June 1994- June 1997)

• Responsible for the resin mix room, coaters and print storage room production areas. Initiated statistical control of the resin/paper coating process and the production chemical formulations.

• Supervised engineering interns for next generation resin chemistry and the optimization of coating process.

• Provided shift supervision in coating, treater and assembly production departments.

• Technical marketing and customer support: Communicated and visited with key customers and help design technical/marketing brochures.

• Completed a $458,000/yr resin raw material savings project, which also streamlined the treating process by 43%.

• Developed resin coating formulations and key partnerships with resin and paper suppliers which improved NevamarTM high-pressure plastic laminate. • Represented International Paper and NevamarTM HPL products on the decorative laminate advisory technical committee of the National Electrical Manufacturers Association (NEMA) to collaborate with industry representatives on the ANSI/NEMA LD-3 technical standard for 1995.

• Supervised technicians and lead the training efforts of the laboratory research/testing equipment such as Dynamic Mechanical Thermal Analysis, Differential Scanning Calorimetry, HPLC, and NEMA LD-3 testing equipment. Honors & Awards: • International Paper, Circle of Excellence Award


Career Accomplishments:
Associations/Societies

AICHE


Consulting Services:
Selected Consulting Examples:
  • Product and Process Design - formulation, interaction and process equipment specifications/RFQ through validation. Manufacturing Solution and Troubleshooting (Six Sigma)Manufacturing location selection and relocation planning. Engineering capital project management Marketing and Business Plans
Recent Client Requests:
  • Expert for consulting on Request for consulant to perform site visit in Japan for TDDS.
  • Expert for consulting on Issues with Gravure Coating.
  • Expert in RFP: Converting Industry.
  • Pressure sensitive tape expert for consulting on Masking tape production.
  • Expert in consulting on migration of dried surfactant solutions.
  • Coating expert for consulting on Turbulent Airflow in Spray Booth Causing Part to Part Inconsitency.
  • Expert in Electrical Coatings for composite RF Parabolic Dish.
  • Converting adhesive expert for consulting on Adhesive applications & technology for medical device packaging.
  • Expert for consulting on Consluting services.
  • Expert for consulting on laminating of UV film.
  • Expert for consulting on planning for future equipment investmenst.
  • Expert for consulting on Transdermal patch development for Cannabinoids.
  • Expert for consulting on coating fuser roller for copier and printer.
  • Expert for consulting on Transdermal Patch Product Development.
  • Expert for consulting on Seeking candidates for technical due diliegnce work.
  • Resin expert for consulting on Resins.
  • Expert in padprint overhaul.
  • Expert in Human Body Ahesives.
  • Expert in Looking for formulations specialist in industrial maintenance coatings and coil coatings.
  • Expert for consulting on 100% Solid Structural Epoxy.
  • Expert in high speed flexographic printing for a site assessment.
  • Surface tension measurement expert for consulting on measurement of adhesive peneration depth v.s gap.
  • Expert for consulting on moist skin friendly adhesive to locate FDA approved adhesive to meet client properties.
  • Expert in US best manufacturing processes for a transdermal drug delivery systems.
  • Expert in Painting process.
  • Expert for consulting on Industrial Paint Shop Setup.
  • Organic chemist expert epoxy for consulting on Epoxy resin method development.
  • Expert for hotmelt issues for consulting on bottle labeling issue.
  • Skin adhesive expert for consulting on Need to Consult on skin patch device -skin adhesives & fabrics.
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:
Recent Litigation Client Requests:
  • Expert for consulting on Goodyear motorcycle tire failure.
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
2001 to 2007   Limerick, Ireland   He had responsibility for product and process scale up at the Adhesives Research, Limerick Ireland facility. The cleanroom optical and electronic adhesive product commercialization was successful.
2009 to   Manaus, Brazil   He successfully developed and trialed a new security solution with this customer.
2009 to   Warsaw, Poland   He successfully developed and trialed new cost effective materials to this customer.
2009 to 2015   New Castle, UK   Expert's Firm UK facility technical product transfer.
2013 to   Toyama, Japan   Pharmaceutical client consulting project
2014 to   Matomoras, Mexico   Automotive client consulting project
2014 to   Quebec, Canada   5 roll toll coating operation

Market Research:
Expert is experienced in cost analysis and in operations/production key performance indicators.

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:
Training/Seminars

Expert has offered a seminar at the Shapiro Negotiating Institute. He has also taken the PTI cGMP Root Cause Analysis and Corrective and Preventative Action (CAPA).

EGMT Graduate Course, Organizational Behavior for Engineering Management, George Washington University EGMT Graduate Course, Quantitative Methods for Management, George Washington University International Paper Company, Kepner-Tregoe RCA Leader Development Institute (LDI), Cordele, GA. International Paper Company, Six Sigma Statistical Design of Experiments, (Process Development and Optimization) International Paper Company, Six Sigma Statistical Data Analysis, Odenton, MD. International Paper Company, Introduction to Six Sigma Statistical Concepts, Ticonderoga, NY. International Paper Company, Rapid Change- Business Communication, Odenton, MD. WatersTM HPLC Preventative Maintenance Pumps, Valves, & Injectors, Boston, MA. ACS High Pressure Liquid Chromatography Theory and Practice, Virginia Tech, Blacksburg, VA. Rheometric Scientific DMTA Operations, Applications, and Preventative Maintenance, Odenton, MD

Supplier and Vendor Location and Selection

Expert has extensive experience specifying cost-effective film, paper, and adhesive tape raw materials.

Expert has a niche for writing specifications and supply/pricing agreements. His project management skills achieve real results, saving millions of dollars year over year.

Other Skills and Services

Expert is highly experienced in the following: Production management, lean manufacturing, six sigma, stage gate product and process development.


 

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