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Resume of RWY, P.E.
Consultant

EXPERTISE AND SERVICES

Metallurgical, Quality, Expert Consultant
Expertise in aluminum extrusion process engineering, lean manufacturing, precision tubing, inventory management systems, green field manufacturing.

This KKAI Associate offers expertise specific to extrusion, drawing, heat treatment and finishing operations, profile, porthole tubing and MPE extrusion, cut to length (saw, rotary and chipless), aging and finishing operations, shape sawing, annealing, heat treatment and finishing operations.

Additional experience includes quality systems, remelting, DC casting, NDT, HO and billet cutting, molten metal treatment, quality assurance, Kaizen methodology, impact forging, metal matrix, rolling, shear face extrusion technology.

This KKAI Associate also has strong background in aluminum wire drawing and aluminum nail manufacturing, mechanical, chemical and metallographic, alloys, heat transfer, and molten metal treatment

PRINCIPAL INDUSTRIES SERVED
Manufacturing, Metals, Automotive, Mechanical, Chemical, Aerospace, Petrochemical

EDUCATION
B.S., Metallurgical Engineering, University of Tennessee

PROFESSIONAL EXPERIENCE
Consultant, Kevin Kennedy & Associates, Inc.

Providing expertise in metallurgical engineering, process engineering, hydro automotive production system (HAPS) lean consulting, extrusion consulting, quality management, ISO 9002 implementation, forensic analysis, and related expertise to a wide variety of clients.

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Case Studies

Project and Process Engineer Mentor, Aluminum Extrusion firm

Acted as a mentor to newly hired Project and Process Engineers. Ensured the manufacturing departments were fully supported during the training period of the new engineers.

HAPS Deployment Manager (Lean Manufacturing), Aluminum Extrusion firm

Was member of the Core Hydro Automotive Production System (HAPS) (Lean Manufacturing) team for the sector.
Deployment of HAPS to the twelve facilities within the Precision Tubing Business Unit. Played key role in the evolution of HAPS from a tools based system to a full planning system that incorporates lean manufacturing techniques and principles into the future state plans of the facility. Was involved in development of capacity, scheduling and inventory management systems in a green field manufacturing facility.

Plant Metallurgist, Aluminum Extrusion firm

Was member of the facility top management. Oversaw all metal technical activities of the plant. Directly supervised personnel in the laboratory. Involved in extrusion, drawing, heat treatment and finishing operations processes.

Extrusion Manager, Aluminum Extrusion firm

Was member of the facility top management. Provided leadership for and management of the extrusion department. Involved in extrusion (profile, porthole tubing and MPE), cut to length (saw and chipless), aging and finishing operations processes.

Manager of Straight Lengths, Aluminum Extrusion firm

Was member of the facility top management. Provided leadership for and management of the Straight Length Department. Involved in drawing, cut to length (saw, rotary and chipless), annealing, aging and finishing operations.

Quality Manager/Plant Metallurgist, Aluminum Extrusion firm

Was member of the facility top management. Provided leadership for and management of the quality department. Oversaw all quality and technical activities of the plant. Was key quality contact for customers. Directly supervised salaried personnel in the quality department. Provided role in extrusion, drawing, heat treatment and finishing operations processes. Developed a cost of quality system for the heat transfer division. Implemented a paperless quality system.

Remelt Operations Manager, Alcan Extrusions/Cressona Aluminum

Was member of the facility top management. Provided leadership for and management of the remelt facility. Provided management of all metal matters for the facility. Provided role in remelting, DC casting, NDT, HO and billet cutting processes. Oversaw the successful on time installation of an emergency water system along with casting control upgrading. Completed equipment search and other activity on upgrading of the molten metal treatment capability of the Remelt.

ADDITIONAL EXPERIENCE

ISO 9002 Implementation Coordinator
Successfully completed all documentation for registration to ISO 9002. Analyses of past successes to address culture change necessary for successful ISO 9002 registration.
Quality Assurance/Technical Manager
Provided leadership for and management of the Quality Department. Successful implementation of the Kaizen methodology for team orientated continuous improvement in the plant.
Quality Assurance Manager
Was responsible for implementation and training of second generation statistical process control. Installation of a metallographic laboratory. Elimination of environmental discharge violations. Development of new alloys. Development of a cleaning and coating operation in the nail painting operation. Development of relationships between grain size, heat treatment, amounts of cold work and degree of headability in the aerospace fastener industry. Development of Al-Li welding wire drawing manufacturing process.
Process Metallurgist
Was responsible for planning and coordinating the technical activities of Quality Engineering in Aluminum and Copper alloy mill.

PROFESSIONAL REGISTRATION
Professional Engineer, AL

Please note that this is an abbreviated CV. A fully detailed unabridged CV is available under special circumstances.

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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax

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