Experience
Sr. R&D Engineer – Compounding Industrialization - Solvay Specialty Polymers
7/2008 – 3/2014 (5.5 years)
Manage the scale-up of compounding processes from lab scale to pilot scale as a member of various product development teams. Responsibilities include defining testing and product specifications, defining process operating conditions, modifying screw designs as needed and verifying processes are translatable to commercial compounding sites.
Improved product quality and process operation through redesign of compounding process and screw configuration for improved mixing.
Oversee process technology transfer to compounding sites within the company and to partner companies worldwide as business needs require.
Support manufacturing sites with any process issues such as problematic feeding, low rates/yields, and poor product quality.
Compounding ultra high performance products such as carbon fiber filled PEEK, highly glass filled high temperature polyamides, transferring process-sensitive formulations.
Transferred product formulations and process operations to partner companies in Asia working directly with engineers and operators in China and Japan.
Determine process capability and control using statistical software to identify areas for process improvement. Skilled in SPC implementation in polymer processes.
Working directly with automotive and consumer products customers to address quality and product
issues.
Sr. Process Engineer – PolyOne Corporation
8/2002 - 3/2004 and 12/2006 – 3/2008
Responsible for process definition, troubleshooting and product quality for key Seabrook customer.
Primary focus is on the continuous production of compounded products based on customer formulations while improving process and product quality and consistence.
Implemented statistical process control as part of the operating discipline.
Providing operating direction and discipline in polymer compounding process.
Regularly approached for knowledge in resin systems, extrusion operations and new process
development.
Technical representation of PolyOne to customer for producer services business.
Process Development of customer products on PolyOne equipment, primarily twin screw
extrusion, reactive extrusion and compounding.
Coordinate process trials of new products
Process troubleshooting technical expertise of hard to process polymer formulations.
Design compounding processes to resolve customer issues and qualify processes for
customer products
03/2004 to 6/2005
Applications Development Leader – Celanese Corporation
Lead the development effort of the Emerging Markets business segment of PVOH focusing on development of a melt processable polyvinyl alcohol product line.
Implemented appropriate use of design for six sigma tools to assess voice of customer, quality functional deployment and implement appropriate solutions to meet customer needs.
Defined melt processing parameters and film quality requirements.
Provided technical service support to troubleshoot customer opportunities.
1/1995 - 4/2002
Resin Development Engineer Chevron Chemical Co./ Chevron Phillips Chemical Co.
Supervisor - Reactive Extrusion Pilot Plant
Developed, optimized and scaled-up reactive extrusion process for the manufacture of OSP® Resin systems. Process involves a multi-component reaction, devolitalization, steam assisted stripping of monomers and pelletization.
Implemented design modifications and improvements for process optimization based on experimental data.
Implemented on-line SPC process control for critical process variables.
Authored process technology manual detailing process development and scale-up engineering.
Invented process component which increased process efficiency by 40%.
Coordinated operator training which brought together plant operations and research technicians to ensure a smooth successful start-up of a new plant operating unit.
Directed the activities of two full-time operating technicians, maintenance technicians and laboratory
personnel in the process and product development of reactive extrusion processes. Trained a staff of 10 operators for training in new process developed in house.
Operated pilot plant with no recordables for 2 years and no first aide incidents for 1.5 years.
Developed include acrylate-based ionomer and modified experimental polymers for scale-up to commercial production processes.
6/94 - 12/98
Development Engineer - Specialty Polymers Technology Chevron Chemical Co.
Responsible for the product development of high value functionalized products produced on high pressure autoclave reactors and reactive extrusions lines. Implemented initial trials of experimental products on full scale production units. Developed polymer formulations into viable products and commercialized 20 new EMA, EVA EnBA and specialty LDPE homopolymer products in 1995 - 1997. Demonstrated the ability of autoclave reactors to produce very high MI and VA resins beyond original design capabilities. Invented autoclave process for new proprietary copolymer for packaging resins. Introduced process improvements resulting in increased process control and reduced
transition times.
10/92 - 6/94
Product Development Engineer - LLDPE Chevron Chemical Co.
Planned and executed experimental programs for the development of new products to support the LLDPE business unit utilizing licensed BP gas phase LLDPE and HDPE technology. Designed experiments to obtain process and product data in the pilot plant which was correlated and modeled for use in scale-up to commercial production. Developed experimental plans for the start-up and initial qualification of a catalyst and prepolymerization unit for catalyst development programs to support the LLDPE and HDPE product lines. Provided leadership to two quality teams for continued process improvement which resulted in the highest operating efficiency of all pilot plant units.
12/89 - 10/92
Engineer - Pilot Plant
Provided engineering for projects and operations in the low pressure pilot plant for the development of polyethylene resins. Responsible for numerous projects exceeding $1.5MM annually. Provided direction and leadership for lead technician and maintenance personnel including the scheduling of a contract crew for construction and maintenance work. Developed the Management of Change Procedure for the pilot plant to meet internal customer needs and plant safety requirements. Certified HAZOP Trainer 1992.
7/2008 – 3/2014 (5.5 years)
Manage the scale-up of compounding processes from lab scale to pilot scale as a member of various product development teams. Responsibilities include defining testing and product specifications, defining process operating conditions, modifying screw designs as needed and verifying processes are translatable to commercial compounding sites.
Improved product quality and process operation through redesign of compounding process and screw configuration for improved mixing.
Oversee process technology transfer to compounding sites within the company and to partner companies worldwide as business needs require.
Support manufacturing sites with any process issues such as problematic feeding, low rates/yields, and poor product quality.
Compounding ultra high performance products such as carbon fiber filled PEEK, highly glass filled high temperature polyamides, transferring process-sensitive formulations.
Transferred product formulations and process operations to partner companies in Asia working directly with engineers and operators in China and Japan.
Determine process capability and control using statistical software to identify areas for process improvement. Skilled in SPC implementation in polymer processes.
Working directly with automotive and consumer products customers to address quality and product
issues.
Sr. Process Engineer – PolyOne Corporation
8/2002 - 3/2004 and 12/2006 – 3/2008
Responsible for process definition, troubleshooting and product quality for key Seabrook customer.
Primary focus is on the continuous production of compounded products based on customer formulations while improving process and product quality and consistence.
Implemented statistical process control as part of the operating discipline.
Providing operating direction and discipline in polymer compounding process.
Regularly approached for knowledge in resin systems, extrusion operations and new process
development.
Technical representation of PolyOne to customer for producer services business.
Process Development of customer products on PolyOne equipment, primarily twin screw
extrusion, reactive extrusion and compounding.
Coordinate process trials of new products
Process troubleshooting technical expertise of hard to process polymer formulations.
Design compounding processes to resolve customer issues and qualify processes for
customer products
03/2004 to 6/2005
Applications Development Leader – Celanese Corporation
Lead the development effort of the Emerging Markets business segment of PVOH focusing on development of a melt processable polyvinyl alcohol product line.
Implemented appropriate use of design for six sigma tools to assess voice of customer, quality functional deployment and implement appropriate solutions to meet customer needs.
Defined melt processing parameters and film quality requirements.
Provided technical service support to troubleshoot customer opportunities.
1/1995 - 4/2002
Resin Development Engineer Chevron Chemical Co./ Chevron Phillips Chemical Co.
Supervisor - Reactive Extrusion Pilot Plant
Developed, optimized and scaled-up reactive extrusion process for the manufacture of OSP® Resin systems. Process involves a multi-component reaction, devolitalization, steam assisted stripping of monomers and pelletization.
Implemented design modifications and improvements for process optimization based on experimental data.
Implemented on-line SPC process control for critical process variables.
Authored process technology manual detailing process development and scale-up engineering.
Invented process component which increased process efficiency by 40%.
Coordinated operator training which brought together plant operations and research technicians to ensure a smooth successful start-up of a new plant operating unit.
Directed the activities of two full-time operating technicians, maintenance technicians and laboratory
personnel in the process and product development of reactive extrusion processes. Trained a staff of 10 operators for training in new process developed in house.
Operated pilot plant with no recordables for 2 years and no first aide incidents for 1.5 years.
Developed include acrylate-based ionomer and modified experimental polymers for scale-up to commercial production processes.
6/94 - 12/98
Development Engineer - Specialty Polymers Technology Chevron Chemical Co.
Responsible for the product development of high value functionalized products produced on high pressure autoclave reactors and reactive extrusions lines. Implemented initial trials of experimental products on full scale production units. Developed polymer formulations into viable products and commercialized 20 new EMA, EVA EnBA and specialty LDPE homopolymer products in 1995 - 1997. Demonstrated the ability of autoclave reactors to produce very high MI and VA resins beyond original design capabilities. Invented autoclave process for new proprietary copolymer for packaging resins. Introduced process improvements resulting in increased process control and reduced
transition times.
10/92 - 6/94
Product Development Engineer - LLDPE Chevron Chemical Co.
Planned and executed experimental programs for the development of new products to support the LLDPE business unit utilizing licensed BP gas phase LLDPE and HDPE technology. Designed experiments to obtain process and product data in the pilot plant which was correlated and modeled for use in scale-up to commercial production. Developed experimental plans for the start-up and initial qualification of a catalyst and prepolymerization unit for catalyst development programs to support the LLDPE and HDPE product lines. Provided leadership to two quality teams for continued process improvement which resulted in the highest operating efficiency of all pilot plant units.
12/89 - 10/92
Engineer - Pilot Plant
Provided engineering for projects and operations in the low pressure pilot plant for the development of polyethylene resins. Responsible for numerous projects exceeding $1.5MM annually. Provided direction and leadership for lead technician and maintenance personnel including the scheduling of a contract crew for construction and maintenance work. Developed the Management of Change Procedure for the pilot plant to meet internal customer needs and plant safety requirements. Certified HAZOP Trainer 1992.