Technical Ceramics Process Expert and Ceramic Market Analyst Including Alumina, Zirconia, Titanates and Composites (1282)
Expertise
Thick/thin ceramic films, technical ceramics, ceramic capacitors, oxide ceramics.
Expertise with ceramic oxide materials: alumina, zirconia, titanites and ceramic composites.
Production of ceramic nanoparticles and nanotechnology materials.
Worldwide market analysis of engineered ceramic materials.
Worldwide patent analysis of advanced materials, including technical ceramics.
Development of production processes for technical ceramics.
Qualification and troubleshooting of newly developed ceramic processes.
Quality control and statistical analysis including SPC, root cause analysis of ceramic processes and ceramic manufacturing.
Experience
Consultant and Market Analyst, 2002-present
Process development, feasibility studies, worldwide market analyses and global patent analyses in the field of advanced materials for U.S. and international firms. Thin and thick-film technologies, materials for pollution control, innovative materials and products, expanding technologies, electronic materials, nanotechnology, and bioceramics.
Bettini Inc., Italy, R&D Director, 2000-2002
Research and development, production, process engineering, and quality control, for a manufacturer of technical ceramics used in textile and mechanical applications.
Directed process improvement and the research and development of oxide and non-oxide ceramic materials: alumina, zirconia, alumina/zirconia composites, titania, silicon carbide, silicon nitride and boron carbide.
Developed binder system for processing new alumina/zirconia nanocomposite.
Introduced Statistical Process Control and revised process procedures to comply with the requirements of the ISO9000 standard.
American Technical Ceramics, Process Engineering Manager,1987-2000
Process Engineering Manager for a $60M manufacturer of electronic components, capacitors. Coordinating, planning, and bringing to completion projects related to process development, process control, and process improvement.
Process areas: qualification and preparation of raw materials, binder preparation, casting of ceramic tape, lamination, binder burn-out, dicing, sintering, termination, electrolytic plating and assembly.
Process activities: 1) Evaluating and qualifying raw materials: ceramic and metal powders, precious metal pastes, various chemicals. 2) Developing formulations of binders, ceramic slurries, and metal pastes. 3) Developing new and/or modifying existing manufacturing methods, process instructions, and procedures to maximize product quality and productivity. 4) Evaluating and implementing the use of new production equipment and assisting in modifying and improving existing equipment. 5) Conducting production feasibility studies, identifying constraints, and recommending solutions. 6) Implementing corporate Statistical Process Control program. 7) Root cause analysis and failure analysis.
Significant cost saving projects: 1) Development of a new ceramic capacitor prepared with nanopowder material. 2) Development of a new binder for low pressure application. 3) Reduction of electrical failures (Dissipation Factor) from 3% to 0.3% ($2 million savings). 4) Qualification of bulk firing resulting in energy savings, higher throughput, and kiln variance reduction. 5) Reprocessing of ceramic tape. 6) 90% reduction of waste solvent used in the dicing area. 7) Maximization of production yields from 75% to 90% within one year.
Senior Process Engineer: Successful development and quality optimization of new multilayer ceramic capacitors. Increased product lots registering “zero defects” from 20% to 70% within 18 months. Cut average time of fabrication by over 60% from 2 months to 3 weeks. Successfully completed 65 R&D and process improvement projects over the course of 7 years including development of new products aimed at expanding corporate customer base.
Ceramic Center, Bologna, Italy, Ceramic Engineer, 1984-1985
Research and qualification of new processes such as granulation, microwave drying, wet continuous milling, and fast firing.
Designed and developed a computer program simulating the process of firing ceramic tiles in a roller kiln.
Honors & Publications
Publications: Process Control in the Ceramic Industry; Energy Consumption in the Northern Italian Ceramic Industry
Professional associations: American Ceramic Society, NICE, ASM International,
American Society for Quality Control
Education
Specialization in Ceramic Engineering (U.S. Masters Degree), University of Bologna, Italy
Chemical Engineering and Material Science, University of Bologna