Aluminum Casting Technology Expert ConsultantThis consultant has expertise in implementation of new casting and melting technologies, bonded particle filters, pumps and degassers to the aluminum die casting, foundry and ingot casting industries. This expert also has experience in manufacturing and engineering consulting to aluminum industry, and new technology management including completion of patents.
This associate offers additional specialization and expertise in manufacture and sale of aluminum casting alloys. This consultant has been an expert witness in litigation. This expert has worked with cost reduction strategies focusing on increased scrap utilization, and reduced melt losses or overall scrap reduction. This associate is highly experienced in areas including aluminum SSM billet and aerospace alloys to the metal casting industry, cost reduction strategies and technical problem solving for foundry and extrusion industries. This expert has involvement with new manufacturing technologies for SSM parts production and precision forging of automotive wheels. Product specifications for die casting and deox products, and development of deox rod and rod feeding equipment for the steel industry are also areas of expertise this associate has.
Notable accomplishments of this associate include successfully modeling the machining behavior of high silicon automotive aluminum engine alloys, and development of manufacturing and metallurgical practices to manufacture the first automotive aluminum wheels for the OEM market in this country. This associate is also experienced in research projects in ingot casting, molten metal processing and metal quality testing.
Consultant, Kevin Kennedy Associates Inc.
Providing metallurgical engineering, aluminum casting technology expertise, engineering and manufacturing consulting, technical services and automotive castings consulting, engineering failure analysis, forensic investigation and analysis, patent infringement expert witness testimony, and related expertise to a wide variety of clients.
Engineering and Manufacturing Consultant, Cleveland, OH
Provided manufacturing and engineering consulting to aluminum industry clients on a broad array of projects:
Provided manufacturing strategy for the U.S. and managed prototype production trials as part of a material qualification for an Australian composite brake manufacturer.
Provided consultation to facilitate the sale of a die casting facility in Tennessee for a Bankruptcy Trustee.
Provided process improvement and casting scrap reduction for client's foundry supplier in India through visitation during casting trials and recommendation of improved gating design for a Major Truck Engine Manufacturer.
Provided process improvement to client's aluminum billet supplier through visitation and equipment recommendations for new casting hardware and molten metal processing improvements for the largest wheel producer in China.
Manager of Casting Technology, aluminum manufacturing company
Was responsible for metallurgical practices at five manufacturing facilities and implementation of new casting and melting technologies, reporting to the president of the company. Brought Semi-Solid Casting to commercial reality in revitalization of a 3-year stagnant project. Prepared strategic plan to better utilize scrap more economically at all casting facilities. Provided key contacts for consideration as potential acquisitions as part of long-range strategy for future growth.
Regional Sales Manager, Product Manager, Metaullics Systems Division of Pyrotek, Inc., Cleveland, OH
Promoted sales of bonded particle filters, pumps and degassers to the aluminum die casting, foundry and ingot casting industry within Metaullics’ largest sales market. Increased annual sales revenue within territory by 15%. Traveled extensively throughout North America to team with Pyrotek sales force as technical representative and coach as part of a sales force consolidation including plant visits to all prospective filter customers. Led an extensive survey of more than 200 customers to establish market share for bonded particle filters and total demand for molten metal filters. Developed customer case histories documenting quantitative benefits of successful molten metal filtration as a marketing tool for new business development.
Engineering and Manufacturing Consultant, Richmond, VA
Provided manufacturing and engineering consulting to aluminum industry clients on a broad array of projects. For a Fortune 100 Financial Institution: Established a technology licensing venture for Semi-Solid Casting. Successfully negotiated an agreement to sell the technology. Managed technology to completion of patents, identified potential licensees and provided industrial production trials of new applications for prospects. For a European-based Primary Aluminum Producer: Developed a business plan for the manufacture and sale of aluminum casting alloys in North America. This included providing customer lists, sales forecasts, and site selection for potential manufacturing and acquisitions. For a Variety of Aluminum Casting and Smelting Operations in the U.S.: Served as an expert witness in litigation and recommended cost reduction strategies focusing on increased scrap utilization, reduced melt losses or overall scrap reduction.
Sales and Marketing Director, Ormet Primary Aluminum Corporation, Wheeling, WV
Sold aluminum SSM billet and aerospace alloys to the metal casting industry. Increased annual sales revenue by 59%. Evaluated, consolidated and developed selected manufacturers’ reps. and reorganized marketing strategy for subsidiary SSM die caster. As part of a business development strategy, organized and chaired semi-solid casting symposium with 50 international speakers attended by over 400 automotive industry decision makers.
Customer Development and Technical Services Director, Metals Division, Reynolds Metals Company, Richmond, VA
Provided technical services to customers of $900 MM metals division, provided cost reduction strategies and technical problem solving for foundry and extrusion customers. As Division member of World Automotive Team, developed business and marketing strategy to capture structural casting growth opportunities in the automotive market. Earned “Supplier of the Year” award from largest ingot customer and increased market share by 50%. Identified and evaluated new manufacturing technology opportunities for Reynolds' international management team including SSM parts production and precision forging of automotive wheels.
Product Manager, New Products Manager, Specialty Products Manager, Recycling and Reclamation Division
Coordinated customer service, product specifications for die casting and deox products. Developed and successfully launched new deox rod and rod feeding equipment for the steel industry through contract suppliers. Managed three reclamation plant departments; salt purchasing, dross reclamation and shipping/receiving. Duties included scheduling and inventory control.
Development Project Director, Product Development Division
Directed a laboratory and university team to successfully model the machining behavior of high silicon automotive aluminum engine alloys. Published results and consulted extensively with manufacturers in the automotive industry to optimize their machining systems. Developed manufacturing and metallurgical practices to manufacture the first automotive aluminum wheels for the OEM market in this country.
Senior Research Engineer, Metallurgical Research Division
Managed research projects in ingot casting, molten metal processing and metal quality testing. Provided process improvement services to 12 production cast houses across North America.