Cooking Monitoring Equipment: For Dog Food Manufacturer, developed method and equipment to measure expansion and contraction of the container lid during the cooking process. This allowed the cooking process to be monitored more directly and the cooking cycle adjusted to optimum performance.

 

MRI Table Manufacture:  Developed a manufacturing process and simulated it for the manufacture of a new MRI table.

 

Rapid Acquisition of Manufactured Parts (Navy): Company President, Jerry Hoskins, was the system engineer for this program while employed by Battelle.  This was a large multi year project that developed a system for printed wiring assemblies and machined parts to allow the Navy to procure out of production printed wiring assemblies and machined parts quickly. These systems were developed and then implemented in several Navy, Air Force, and Army depots and logistics centers.

 

Vinyl Products Manufacturer:  Developed and tested method to eliminate buildup of materials on die lip.  

 

Oil Rig Pipe Producer: Designed, built, tested, and implemented electronic instrument to monitor and display table position as a function of pipe diameter.

 

Glass Tubing Manufacturer:  Designed, built, tested, and implemented system to track hot glass flow profile and automatically adjust temperature profiles to control the profile.

 

Total Productive Maintenance: Completed TPM evaluation for ink jet cartridge manufacturer. Identified $16M in savings with the pilot program savings of $2.6M.

 

Oxygen Sensing in High Temperature Glass Melting: Developed oxygen sensor, mounting device, and electronic system to continuously monitor and report excess oxygen directly in the combustion process in large glass melting operations. System was implemented across the company with savings of several million dollars.

 

Manufacturing process plan: Developed the methods and projected cost for manufacture of Turbo-generators for a Turbo-generator startup company.

 

Processes Definition for Tier 1 Auto Supplier:  Identified critical processes for implementation of ISO TS16949.

 

Capacity Expansion Analysis: For photonics Manufacturer developed design to achieve a capacity increase of 7X.

 

Energy Balances: Energy balances performed to define heat losses and make improvements.

 

In-line Parts Washing:  Specified, tested, and implemented an inline parts washing system that allowed this manufacturer to convert from vapor degreasing in batch mode to one-piece continuous flow.

 

In-line Stress Relief:  Converted stress relief from a large oven with long cycle times to small multiple units that allowed company to implement a flow process and eliminate the large batch processing.

 

Controlled Experiments:  Developed and ran critical experiments to define the key input parameters that could be used to control the outputs.  This allowed those key parameters to be controlled with an improvement in process capability.

 

Plasma Coatings: Developed a plasma spray process to apply a thin coating of platinum to Zirconia. Tested for adhesion and durability.