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Resume of YLO
Consultant

EXPERTISE AND SERVICES

Automotive Brake Design, Automotive Braking Systems, Expert
Expertise in material selection and specification, material analysis, materials development, and failure analysis of automotive brake components and braking systems with specialization in the analysis and design of cast iron braking components.

This consultant offers many years of experience in the design and development of automotive braking systems and components along with extensive knowledge of the manufacturing processes and quality systems used to produce these safety critical components.

Wide-ranging experience includes trouble-shooting and problem solving using Shainin, Taguchi and Six Sigma problem solving techniques. This consultant is highly experienced in the evaluation and analysis of safety related failure modes and their effects including fatigue analyses, corrosion analyses, wear analyses, and analyses of combined failure modes

PRINCIPAL INDUSTRIES SERVED
Automotive, Metallurgical, Iron Castings, Ferrous Heat Treating

EDUCATION
MS, Engineering Materials, University of Michigan
BS, Material Science and Engineering, Michigan Technological University

PROFESSIONAL EXPERIENCE
Consultant, Kevin Kennedy & Associates, Inc.

Providing expertise in metallurgical engineering, materials engineering, mechanical engineering, product engineering, automotive brake engineering, automotive brake design, automotive braking systems, iron castings technology, failure analysis, materials processing development, and related expertise to a wide variety of clients.

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Case Studies

Materials Technical Specialist, TRW Automotive

Was responsible for the selection and specification of materials, heat-treatments, and finishes used in all North American designed foundation brake components. Managed various material, heat treating and finishing development projects for advanced foundation brake component designs. Developed and implemented unique hexavalent-chromium-free zinc electroplating process for cast iron caliper housings. Developed low-lead aluminum alloys for internal brake systems components. Reviewed, approved and developed foundation brake component suppliers for critical material processes including castings, forgings, heat-treatments, and plating and paint/coating finishes. Conducted supplier quality audits and reviews for casting, heat treating and plating processes. Responsible for failure analyses and problem resolution activities for material and/or material process related quality issues for foundation brake components manufactured by company. Developed and implemented new materials laboratory test procedures and analyses methods. Developed analytical method for quantifying the relationship between microstructural variations in the casting to wear variation of the finished gray cast iron rotors. Provided technical and engineering support to internal manufacturing facilities to resolve quality and manufacturing issues.

Product Engineering Manager, TRW Automotive

Managed group of engineers and designers responsible for the design and validation of brake rotors, brake drums, and wheel hubs for passenger and light truck vehicles. Created and implemented brake rotor and brake drum design guide documents to maintain and justify the design history of lessons learned for the group. Created and implemented department standards for drawings, material specifications, design failure mode and effects analyses (DFMEA), and design validation plans and reports (DVP&R) in order to stream-line the design process. Directed implementation of PC-based thermal and stress finite element analyses for rotor and drum sizing and thermal management analyses using SolidWorks and Geostar software packages. Developed several new component validation test methods to improve reliability of products tested and reduce testing costs. Developed and implemented new job descriptions and career path strategy for product designers and engineers. Conducted market analyses for evaluation of the future business potential for brake rotor, drum and hub products.

Principal Product Engineer, Kelsey-Hayes

Designed and validated various passenger car and light truck brake rotors and drums manufactured for various customers. Directed various laboratory and component testing for rotor and drum development and validation testing. Managed rotor and drum material development projects including metal-matrix composite rotors and drums and unique lot-rot corrosion protective coating process for brake rotors. Designed and validated first production aluminum metal-matrix composite rotor design for rear rotor application in the 1997 Plymouth Prowler. Conducted various material and heat treat development projects for advanced rotor and drum designs. Trouble-shooting of material and/or process related quality issues for brake rotors and drums manufactured by company. Reviewed and approved casting suppliers for rotor and drum castings. Managed materials laboratory work and personnel with 3 lab technicians.

Materials Engineer, General Motors

Conducted complete failure analyses for automotive chassis components. Conducted metallurgical and metallographic analysis and characterization of materials used for automotive components from development and validation programs. Created and implemented material specifications for use in automotive chassis components. Reviewed and approved material selection and specification for automotive braking and exhaust system components. Supported material and process development for new automotive braking and exhaust system component applications. Trouble-shooting of material and/or process related quality issues for automotive chassis components.

PROFESSIONAL AFFILIATIONS
Member of American Society of Materials (ASM)
Member of Society of Automotive Engineers (SAE)

PUBLICATIONS
Author of numerous reports, presentations, and seminars on topics related to and including ceramic superconductors, residual stresses on gray iron brake rotors, and gray cast iron brake rotor metallurgy. Awarded patents for composite brake rotor design, manufacturing method for producing composite brake rotors, and near net shape rotor design.

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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