Senior Project Engineer, R&D
Conceived and initiated development of a new filter media concept, SynteqTM XP.Planned and led concept validation, reduced to practice, and transferred to development personnel.These front-end efforts included leading 4+ people, spending about $350K, and approximately 4 calendar years. The material is a breakthrough high performance platform filter media used in diverse applications including liquid, mist, and air filtration.SynteqTM XP created new business opportunities, sales of product using SynteqTM XP exceed $2M / year and are growing rapidly.Seven US Patents issued; two for SynteqTM XP, five for related matter.
Translated a filter media-manufacturing process concept into reality.Member of a multi-discipline team that demonstrated concept feasibility and its potential to increase performance more than 50% while reducing cost approximately 30%.Used CAD to modify a large machine, design critical components, and used Statistica to plan DOE process experiments and analyze data.Applied Fluent CFD to verify the existence of a problem condition, CFD result used to help resolve the problem condition.
Created an Access database for gas chromatograph mass spectrometer (GCMS) data that reduced data analysis labor by more than 95%.Use of the database resulted in about $3M labor savings and a substantial gain in GCMS productivity.Used from 1999 to present.
Conceived, initiated development, and influenced management and Board to implement a systematic problem solving method, a global engineering productivity tool that harnessed solver optimization methods to automate engineering design.Led 11 people from two business unit-engineering groups and two consulting firms to create prototype technology demonstrators for validation and assessment.Resources expended for assessment: about $530K and 1.5 calendar years.The system is now being implemented with 5+ dedicated staff.
Applied time series analysis to 4+ years of data to develop a predictive model and decipher the relationship between filter loading and variations in relative humidity (RH).Business unit considered using a predictive model or a controlled test environment to ensure fair comparisons between tests conducted during different seasons (environmental conditions).Time series analysis produced several surprises and insights, however capital investment to control test environment was required.
Designed, built, assembled, and debugged 5+ automated test bench systems that accelerated the development of advanced filtration media, products, and models.Designed hardware, user interface, VB data acquisition and control software, Access databases, system controls, and data acquisition hardware.Developed and used statistical models based on acquired data.Worked with vendors and collaborated with various groups and experts as needed.
Used Design of Experiments (DOE) extensively to solve a wide variety of difficult problems; modeled multi-layer depth loading gradient filter media, designed nano-fiber composite gradient media, controlled fluid mixing, determined root cause of high velocity filter resistance, reduced product performance variation, modeled filter media efficiency and life for depth loading media, and more.Resolution of these problems produced a media manufacturing process, foundation for a new platform filter media, a problem solving method, and value streams from several new products and inventions.