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Resume of DAW
Consultant

EXPERTISE AND SERVICES

Director of Manufacturing Consulting, Mechanical Engineer, Automotive Design Manufacturing Engineer, Consultant, Specialist, Forensic Analysis Expert, Product Liability Expert Witness Testimony, Patent Infringement, Expert Witness Testimony, Engineering Consulting Services
Expertise in development of automotive product manufacturing strategies, optimization of manufacturing processes, materials selection for manufacturing, quality assurance, control, and leading program implementation for specific products and families of products.

This KKAI Associate offers automotive design manufacturing expertise with special interests in high-volume assembly, electronics, semiconductor, and consumer product manufacturing, hybrid, PCB (printed circuit board), and PWB (printed wiring board) packaging, design for mechanical assembly, wave soldering, and metal surface finishing, flip chip applications.

Specialization includes ABS applications, thermal package design, thermal buffer systems for power IC's, high density PWB's, flexible robots, surface mount technology, SMT, testing, development of patentable new manufacturing processes, automotive electronics manufacturing, development of company trade secrets, automotive electronic assembly issues, process of product validation, mechatronics, smart elecro-mechanical systems.

Also highly experienced regarding single digit ppm, paint, spray, dip, and seal options for PCBs, off the shelf IC's, flip chips in automotive electronics, flip chip soldering fluxes, clean or no-clean processing, environmental friendly product design, IC's or substrates, power dissipation, milliwatt to kilowatt, embedded electronics, advanced product development viable, and the future of automotive electronics

PRINCIPAL INDUSTRIES SERVED
Automotive Design Manufacturing, Electronic Packaging Assembly, Semiconductors

EDUCATION
BSME University of Missouri, Rolla, Missouri

PROFESSIONAL EXPERIENCE
Consultant, Kevin Kennedy & Associates, Inc.

Providing project management, mechanical engineering, manufacturing engineering, electronics design and manufacturing consulting services to a wide variety of clients.

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Case Studies

Advanced Engineering, Delco Electronics Corporation, Kokomo, IN

Managed an engineering group responsible for the development of innovative product packaging designs, the manufacturing processes necessary to implement these designs in high volume production, and develop/perform the necessary testing to prove the design capable for its application.

A major accomplishment of this group was to develop a flip chip on laminate system capable of being used in engine compartment and on-engine applications. This technology went into production on specific engine controls and ABS (antiskid braking systems) applications with significant product cost and size reductions.

Other developments include; Design For Manufacturing, improved thermal package designs, thermal buffer systems for power IC’s, high density and higher temperature PWB’s (4 mil lines and spaces), flexible robots for manufacturing, gold wire bonding to PWB’s, solder jetting, and conductive adhesive.

Technical Fellow, Delco Electronics Corporation

Automotive Design Manufacturing Engineering, Delco Electronics Corporation, Kokomo, IN

Managed an Advanced Manufacturing Engineering group charged with the global corporate implementation of surface mount technology (SMT) on Delco Electronic PWB products (radios, engine controls, heater/air controls, etc.). Coordinated international rollout of manufacturing systems at global assembly sites.

Major developments include three generations of high volume component placement equipment, component tape and reel packaging specifications (chips and IC’s), product design specifications for efficient manufacturing, improved component designs and tolerances for improved placement, solder and glue development, solder and glue printing, glue cure, solder reflow, (3 generations), flux cleaning, X-ray placement inspection, electrical test, in-line processing with error-proof techniques, and multi-product SMT (surface mount transistor) assembly lines.

Automotive Design Manufacturing Engineering, Delco Electronic Corporation, Kokomo, IN

Provided project coordination for manufacturing strategy, high volume hybrid SMT assembly, leak proof sensor cell assembly, leak proof plastic housing assembly, and product flow through trimming, test, and final packaging for the first generation pressure sensor, and managed startup of the facility.

Automotive Design Manufacturing Engineering, Delco Electronics Corporation, Kokomo, IN

Coordinated assembly strategy, internal development of special equipment for assembly and test for bridge audio IC, and coordinated the start-up of facility.

Automotive Design Manufacturing Engineering, Delco Electronics Corporation, Kokomo, IN

Served as a part of a team, which developed the Diode Trio and Button Diode rectifiers for automotive charging systems. Coordinated equipment with vendors, worked “Design For
Manufacturing” issues between equipment and produc designs, started up facility and supported initial production.

Manufacturing Engineering, Delco Electronics Corporation, Kokomo, IN

Floor support Engineer for battery charging diode and electromotive power diode wafer processing and test.

PROFESSIONAL AFFILIATIONS
Surface Mount Council Member (steering team for standard committees of IPC, EIA, and SMTA)
Delco Electronics Corporation JISSO representative (JISSO replaced the Surface Mount Council as a global team to promote international standards)

PUBLICATIONS
Numerous publications and development of patentable manufacturing processes related to automotive electronics manufacturing, development of company "trade secrets", automotive electronic assembly issues, process of product validation, mechatronics, smart elecro-mechanical systems, environmental friendly product design, embedded electronics, advanced product development, the future of automotive electronics and more.

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

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Case Studies

Director of Manufacturing Consulting, Mechanical Engineer, Automotive Design Manufacturing Engineer, Consultant, Specialist, Forensic Analysis Expert, Product Liability Expert Witness Testimony, Patent Infringement, Expert Witness Testimony, Engineering Consulting Services
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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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