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Polymer and Emulsion Process Development Expert

Technical Consultant #2277


Expertise

  • Vinyl acetate homopolymer, vinyl acetate ethylene copolymer and acrylic emulsion process development.
  • Vinyl acetate ethylene PVOH spray dried polymer process development.
  • Process and product scale-up and technology transfer from lab to pilot to manufacturing across all market areas of the emulsion business.
  • Identification and deployment of research and development best practices across global technology organizations.
  • Deployment and use of electronic laboratory notebooks to replace paper.
  • Project management for large novel research and development projects and portfolio management that relies on analysis and modeling of both the technical and financial aspects of each opportunity.
  • Stage-gate work process.
  • Innovation work processes.
  • Research and development change management.
  • Manufacturing operating procedures.

Experience

Independent Consultant, Present

Air Products and Chemicals Inc., Allentown, PA, Project Manager, 1984 - 2009

  • Provided project management leadership for $8 million annual budget novel lithium battery material focused on emerging HEV/PHEV battery markets.
  • Led feasibility study to assess the value of electronic laboratory notebooks to replace paper notebooks across global technology organizations.
  • Identified productivity savings of at least 30 minutes per week and up to 10 hours per week for research and development technologists as business case.
  • Presented results of pilot trial of electronic laboratory notebooks at Association of Laboratory Managers Conference (ALMA).
  • Provided financial models and templates to assess new business and technology opportunities across all global technology and commercial development organizations.
  • Designed, developed and deployed a global research and development intranet portal as part of the new Microsoft SharePoint environment for knowledge retention and sharing.

Manager, Process Development

  • Led deployment of best practice research and development work processes across the electronics, performance materials and corporate research and development organizations.
  • Developed and implemented a standard approach for financial analysis of technology programs and projects.
  • Deployed a common stage-gate development work process across all global Air Products technology organizations.
  • Developed, trained and deployed a common approach to financial analysis of new offerings which led to being able to place a present and future valuation on what the $140 million per year research and development spending is worth at Air Products.
  • Provide a common set of metrics for project valuation and portfolio management across the corporation.
  • Led, mentored and coached multiple stage-gated (over $5 million per year spending) technology projects for novel advanced materials focused on electronics, battery materials and nano-materials markets.

Asset and Process Technology Manager

  • As a dual Research and Development Business Manager, developed and led portfolio of global development programs and projects for the Air Products Polymers emulsions business.
  • Managed process development group, new product development, process and quality improvement, maximization of capacity and capital utilization programs for the 300 million pounds, per year business.
  • Successfully deployed a "best in class" reactor technology system design in both a California and a Mexican plant cutting cycle times by more than half and doubling plant capacity saving $20 million in capital expansion.
  • Managed process development group and pilot plant successfully, expanding pilot plant with $2 million capital expansion to support "best in class" development.
  • Pilot scale and manufacturing support for doubling capacity of VAE spray dry business.

Manager Process Development

  • Managed process development group that included 24 engineers and technicians, 2 pilot plants, and quality improvement programs in support of the overall, 750 million pounds, per year emulsions business.
  • Developed technology platform plan which served as the basis and key input for developing the business strategy for this $300 million per year revenue business.
  • Led cross functional group that increased system-wide capacity 30% with no cost and low cost capital options, via debottlenecking from a sold out position saving over $10 million in capital.
  • Served on due diligence teams and provided technology support of domestic and international acquisitions that explored a Brazil expansion and led to expansion into Mexico and Korea.

Principal Process Engineer/Section Manager

  • Led numerous process and product scale-up activities from lab to pilot to manufacturing across all market areas of the emulsions business.
  • Actively involved in due diligence and start-up of two domestic acquisitions.
  • Documented a technology transfer work process.

BF Goodrich Chemical, Independence, OH, Sr. Process Engineer

  • Process design for the central engineering group.
  • Major projects included doubling the capacity of a specialty manufacturing facility, debottlenecking PVC fluid bed and rotary dryers, and an increase in polymer latex capacity by 50%.

Davy McKee, Independence, OH, Process Engineer

  • Process design for a wide variety of chemical and petrochemical capital projects.
  • Major projects included plant designs for several ethylene oxide and ethylene glycol plants, specialty polymers and refineries.

Honors & Publications


Credentials

  • Selected top manager at Air Products for a five part Leadership Education series (part of a group of 200).
  • Completed internal education programs: Innovation, quality management, statistics, statistical design, and continuous improvement.

Academic and Professional Affiliations

  • National team captain for Air Products Leukemia and Lymphoma team.
  • The Ohio State Alumni Association.

Education

  • M.B.A. Case Western Reserve University, Cleveland, OH
  • B.S.Ch.E. The Ohio State University, Columbus, OH
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