metalworking chemical technology, lubrication, tribology experts resumes
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Resume of ZXU, Ph.D. Consultant
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  • Metalworking Chemical Technology
  • Electrochemistry
  • Lubricants
  • Metalworking Fluids
  • Chemical Management

This expert received a Master's Degree in Fluid Dynamics from the University of Michigan.

This expert earned a Doctorate Degree in Analytical Chemistry and Electrochemistry from the University of Texas.

This consultant also completed Business Management workshops and seminars at U of M, Ann Arbor, MI.

Metalworking Chemical Technology, Lubrication, Tribology Experts Resumes
 

This consultant has specific knowledge in the fields of metalworking chemical technology, analytical chemistry and oil and gas production improvement. Exceptionally strong in analytical instrumentation, techniques and methods, working knowledge of current Good Manufacturing Practices / Good Laboratory Practices / ISO /QS.

Expert in metalworking fluids technology and lubrication management. Excellent in all chemical and mechanical engineering aspects of the design, techniques and associated chemicals for oil and gas well fracturing and acidizing to increase production.

Expert at negotiating / managing strategic supplier relationships with both small and multi-billion dollar companies. Excellent at working collaboratively with internal core business departments and appropriate customer/client departments to accomplish product conversions, grow contract footprints and add new adjacency business with sustainable year over year revenue, EBITDA and EVA gains. Additional strengths include matching appropriate analytical techniques and methods to the needed analysis, analytical methods development, technical competitive metalworking product and application understanding and analysis: lubricants, coolants, straight oils, process cleaners, and corrosion inhibitors. Value proposition proposal writing and presentation, commodity and specialty chemical sourcing and cost analysis, supplier continuous improvement programs that accrue annual margin growth, directing high level business affairs and effectively associate with plant floor personnel, problem solving, and team building are additional specializations.

Consultant, Kevin Kennedy Associates Inc.

Providing expertise in metalworking chemical technology, metalworking fluids technology, lubrication management, product analysis and understanding of lubricants, coolants, straight oils, process cleaners, and corrosion inhibitors, and related expertise to a wide variety of clients.

 

Global Director Technical Services and New Services, Haas Total Chemical Management, West Chester, PA

Formulated and implemented technical improvement plans for all 25 metalworking chemical management programs, including metalworking fluid, metallurgical and Quality Assurance Laboratories. These were contracted programs with major automotive manufacturers and related automotive suppliers. Negotiated sustainable strategic alliances with chemical suppliers that maximized margins and continuous improvements. Introduced alternative product and process technologies that maximized cost performance effectiveness. Assured world-class quality of all analytical instrumentation, analyses, data and information from each on site analytical chemical laboratory as well as corporate chemical laboratory. Collaborated with appropriate internal and customer / client departments to implement and optimize product and process conversions. Participated in / accomplished enterprise sales. Accomplished Business Case Analysis of all aspects of potential new chemical management and adjacency business, manning, logistics, pricing, to assure EVA targets were met and were sustainable. Reported to COO. Reviewed and / or developed required analytical methodologies: Wet Chemistry, FT-IR, GC, GC-MS, HPLC, DSC, Durometer, Tensile Strength, Humidity Chamber, Phosphate Coatings testing, Particle Counts and Sizing, XRF, XRD, SEM, ICP, AA Assured all analytical instrumentation continuously complied with QS9000 type requirements for each on site analytical chemical laboratory. Implemented numerous lubrication, coolant and other metalworking product conversions that, in association with Strategic Supplier agreements, resulted in multi-million dollar sustained margin increases. Developed and sold "plant services" type adjacency businesses at several programs. Plant Services ranged from managing wastewater treatment plants and powerhouses to lubrication management to metallurgical analysis to performing routine manufacturing plant maintenance. Developing these businesses included specifying appropriate chemicals / lubricants to be utilized. Used co-developed unique Task Management Database to optimize efficiencies – seven figures in new business – 20% margin improvements in associated core chemical management programs. Implemented co-developed custom versatile Technical Database across all metalworking programs – reduced personnel requirements while improving customer measured program quality – seven figure cost reductions. Managed the development of a number of new Myco bacteria resistant coolants via strategic suppliers for a major automotive client to avoid possible health related issues including hypersensitive pneumonitis and airborne nitrite issues. Assured the safest, most cost performance effective biocides were utilized at the correct concentrations for all coolant applications. Converted axle gear finishing Lapping Compounds to reduce maintenance caused production downtime by some 75% for a major automotive manufacturer. Replaced lapping and reduced phosphating as hypoid axle gear finishing steps with isotropic superfinishing at a major automotive supplier. This process is typically applied to racing car gears, helicopter gear boxes, battlefield tank transmissions and the like where a break in period is not feasible and where superior surface wear characteristics are required. Superfinishing produced[s] significantly improved gear surface finish which yielded substantially fewer break in period related failures and associated warranty costs, reduced gear noise and provided an overall superior wearing gear. It also reduced the number of steps in the manufacturing process, which resulted in lower overall operating cost and increased gear throughput. Negotiated agreements with major USA, Canada and Mexico Strategic Product Suppliers that resulted in multi-million dollar annual margin gains. These more than doubled the margin with one enterprise client. Was an integral member of Enterprise sales Team that generated several multi-million dollar clients. Served as assistant Plant Manager for $5MM cGMP compliant specialty chemical manufacturing plant. Rejected the business or altered tens of new chemical management business proposals to assure targeted profitability.

 

Metalworking Division Operations Manager, Haas Total Chemical Management, West Chester, PA

Recruited to reverse deteriorating automotive powertrain chemical management business. Challenged to reverse over a year of operating losses in this high technology multi-million dollar niche business. Full P&L and budgeting responsibility for all business operations (contract revisions, staffing, operations, logistics, inventory management). Assured world-class quality of all analytical chemical instrumentation, daily analyses, data and information from each on site laboratory as well as Corporate Chemistry Laboratory. Implemented numerous on and off line fluid control instrumentation – filtration modules, sampling modules, air entrainment measurement devices, fluid operating parameter measurements and controls for coolants, process washer cleaners, lubricants, phosphate metal surface treating and metal heat treating to improve operating efficiencies and minimize production downtime. Made a number of coolant conversions to products that improved tool life by 20% to 40%. Tooling cost savings equated to more that the entire cost of the coolants. Replaced a number of low viscosity synthetic coolants that function primarily by inverse soluble polymers to provide very high lubrication at the high temperature tool – part interface, but provided minimal conventional lubrication and corrosion inhibition with state of the art (synthetic ester, amide, etc.) coolants that provided superior high temperature lubrication, low temperature lubrication and substantially improved corrosion inhibition. These replacements saved manufacturing clients millions of dollars in corrosion related machining equipment repairs and component replacements. Altered contracts to assure profitability or moved away from non-profitable contracts. Guided the Division from a seven figure operating loss to multi-million positive operating margin in 3 years. Grew revenues multi-fold, primarily via additional sales. Recruited uniquely talented – relationship, technical and business – managers for key programs to assure margin sustainability, provide for business growth in a highly competitive marketplace and provide for succession. Launched 12 new metalworking chemical management programs, all with sustainable profitability.

 

Complex Manager, Delphi Saginaw Steering Systems site, Saginaw, MI, Castrol Industrial, Chemical Management Services, Naperville, IL

Was promoted to implement a new $10 million metalworking chemical management contract with Delphi. Managed six autonomous automotive parts manufacturing facility chemical management programs located within Saginaw, MI. Responsible for staffing, operating margin and product conversion accountability. Managed the 6 plant analytical laboratories focused on functional control analyses for coolants, straight machining oils, process washer cleaners, lubricants, drawing compounds, stamping & forming compounds, phosphating systems and heat treat / quench chemicals. Maintained all analytical equipment in accordance with QS9000 type requirements. Co-developed with the on site Delphi Corporate analytical laboratory alternative instrumental analysis methods to those used in the plants to assure Incoming metalworking fluid and wastewater treatment chemicals quality and to assure validity of in plant analytical methods. Generated chemical treatment programs for various wastewater treatment and powerhouse facilities within General Motors USA. These facilities included conventional acid-alum systems, acrylate based polymer systems, starch based polymers and biological systems with varying discharge requirements. Powerhouses were primarily lower pressure steam generating boiler-based systems. Specified chemicals, concentrations, delivery equipment and instrumentation, plus application timing. Changed a number of drawing, heat treatment, warm forming and stamping chemicals to improve efficiencies, plus reduce scrap and reworked parts. Achieved first year margin of 160% of Forecast. Reformulated contractual performance metrics to include sharing process savings dollars. This added 50% to Program margins. Always exceeded contractual customer expectations, including savings goals. More than quadrupled the quantity and dollar volume of Castrol coolants and in-process cleaners used in these manufacturing plants. Continuously grew and more than doubled margin during tenure. Generated chemical treatment programs for various wastewater treatment and powerhouse facilities within General Motors USA. These facilities included conventional acid-alum systems, acrylate based polymer systems, starch based polymers and biological systems with varying discharge requirements. Powerhouses were primarily lower pressure steam generating boiler-based systems. Specified chemicals, concentrations, delivery equipment and instrumentation, plus application timing. Changed a number of drawing, heat treatment, warm forming and stamping chemicals to improve efficiencies, plus reduce scrap and reworked parts.

 

Program Manager, General Motors, Lansing, MI, Engine Plants, Castrol Industrial, Chemical Management Services, Naperville, IL

Joined Castrol Chemical Management to implement new $4 million metalworking chemical management contract at 2 automotive engine manufacturing plants and 1 stamping plant. Operating margin and product conversion accountability. Managed two plant analytical laboratories and accomplished testing as required – Wet Chemistry, FT-IR, GC,GC-MS, HPLC, DSC, Durometer, Tensile Strength, Humidity Chamber, Blank Wash testing, Particle Counts and Sizing, XRF, XRD, SEM, ICP, AA Added Lubrication Management to Program scope – included assuring right lubricant chemistry (base lubricant, base lubricant molecular weight range, viscosity range and chemical additives) for every manufacturing and support application (high pressure hydraulics for stamping, low pressure hydraulics for moving machining / manufacturing equipment components, machine slide ways, small pump to heavy duty drawing equipment to wastewater mixing gear lubricants, both high speed and low speed spindle lubricants, high temperature, high wear compressor lubricants) Provided chemicals and technical services for two wastewater treatment and powerhouse facilities [boilers for process steam generation and plant building heating, plus cooling towers for manufacturing process heat control]. Converted automobile body panel stamping chemicals for improved finish and throughput. Achieved first year margin of 200% of Forecast. Protected the six figure Castrol coolant business and grew it to seven figure business by replacing competitive coolants during tenure. Added Lubrication Management to Program scope – 20% additional margin. Provided chemicals and managed two wastewater treatment and powerhouse facilities. Replaced automobile hood stamping chemicals for improved finish and throughput.

 

Technical Services Director, Service Fracturing Company, Pampa, TX

Accomplished laboratory analyses to determine best oil and / or gas stimulation fluids, Wet Chemistry, Rheology, Foam Quality, Particle Counts, Corrosion Inhibition, Fluid Particulate Carrying Capacity, Permeability, Porosity, Core Crush Strength, Formation Chemical Compatibility, Produced Fluid Chemical Compatibility, etc. Generated acidizing and fracturing proposals for oil and gas well stimulation treatments. These ranged from conventional and gelled acid to conventional water based cross linked and gelled fluids to combinations of these fluids with Methanol, Nitrogen and heated Carbon Dioxide. Maintained security, records and nuclear licenses for transportable nuclear fluid density measurement devices. Modified stimulation fracture software to more accurately predict fracture width, height and length and thus increases in oil or gas well productivity. Sourced all chemicals – commodities: acids, Nitrogen, Carbon Dioxide, organic solvents; specialty chemicals: guar gums, cellulosic gums, crosslinking agents, scale preventers, paraffin dissolution chemicals and corrosion inhibitors. Managed client relationships for non-routine services.

 

General Management, Progressive Services Company, Mt. Pleasant, MI

General Management of a 6 person oil and gas well cementing and acidizing service company; sales, marketing, procurement, staffing, logistics, operations. Contracted long term with Michigan Natural Gas Co. and Consumers Power Co. to maintain their numerous underground gas storage wells. Provided pressure control, wellbore integrity and well flow improvement services. Provided on site truck mounted pumping equipment, chemicals and associated services to these primarily remote locations. Contracted, designed and specified chemicals for conventional cementing, acidizing, and paraffin dissolution mobile services at the well site or production site for Michigan oil and gas producers on a job basis. Maintained analytical laboratory and performed analyses to optimize cementing, acidizing, paraffin dissolution and pressure control programs: primarily Wet Chemistry, Rheology, Permeability, Porosity, Corrosion Inhibition and Cement Hardness

 

Corporate Fluids Engineer, Dowell Division Headquarters, Tulsa, OK, DOW Chemical Company, Midland, MI

Developed, marketed and sold drilling fluid polymers and programs that utilized these polymers. Developed, marketed and sold chemical additives for cementing, acidizing and fracturing oil and gas well treatments. Tested most proposed products, product modifications and formations (reservoir rock): Wet Chemistry, Emulsion Stability, Rheology, Permeability, Porosity, XRD, Electrophoresis, etc. Trialed at the well site, documented the results, recommended and made modifications to chemicals and protocols used to further improve the applicability and effectiveness of drilling polymers and stimulation chemical additives.

 

Group Leader Analytical Services, DOW Chemical Company, Corporate Analytical Laboratories, Midland, MI

Managed Emission Spectroscopy and Wet Chemistry Analytical Groups (8 – 13 people). Groups provided non-routine and routine analytical services for Dow Worldwide; utilized cGLPs. Chartered to develop new analytical tools and methodologies. Introduced electro deposition coupled flameless atomic absorption. Developed dc – plasma for the vacuum UV spectrum. Introduced and developed radio frequency plasma emission spectroscopy. Developed electrochemical and spectroscopic methodologies for determining sub-parts per billion level inorganics. Applied unique new electrochemical, x-ray, absorption and emission spectroscopic analytical techniques and methods both on-line and in-lab for specialty chemical and pharmaceutical manufacturing plant process control. Integrated cGLPs into GMPs in pharmaceutical plants. Utilized nuclear, x-ray fluorescence, x-ray diffraction, ion chromatography, electrophoresis, infra red, GPC, GC, GC-mass spec, liquid chromatography as laboratory and process management tools. Sold highly sophisticated instrumental analytical services to external clients. Interim manager polyglycol ether manufacturing plant.

Case Studies

Failure Mode Investigation of Automobile Engine Manufacturing Plant Machining Centers
Advanced Technology Coolants Generate Improved Tool Life and Increased Production
Reduced Air Entrainment Coolant Stops Auto Maker's Eight Figure Production Losses
Plant Services Task Tracking and Measurement Software Package Measurably Improves Plant Maintenance

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