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Resume of KFC, PhD
Consultant

EXPERTISE AND SERVICES

Industrial and Management Systems Engineer, Metallurgical Engineer, Manufacturing Process, Materials, and Metals Processing Consultant, Accident Investigation, Accident Reconstruction, Specialist, Forensic Analysis, Investigation, Product Liability, Expert Witness Testimony, Engineering Consulting Services
Expertise in manufacturing processes, materials, and cost analysis, metals processing and the design and manufacture of dies and molds for forging, and extrusion.

Extensive knowledge regarding permanent mold and pressure die casting, stamping and press forming, rapid prototyping for die castings using the plaster mold process, group technology and computer aided engineering systems.

Other areas of specialty include materials science, metallurgy, casting, welding, and physics, process development and quality engineering for gray, ductile and malleable iron foundries manufacturing of automotive piston rings, cylinder sleeves, valve lifters and camshafts.

This associate's experience includes failure analysis of dynamometer tested, racing, and customer returned engine components, stainless steel propellers and pre-combustion chambers for diesel engines, material handling injury expert witness, die casting defect analysis, and manufacturing systems expert testimony.

Additional experience includes trim press problem resolution, machine injury expert testimony, automation option evaluation, machine injury expert witness, and wrongful death expert testimony.

Additionally, this associate offers expertise related to production line assessment, training program development, production line layout evaluation, production line downtime analysis, foundry quality program development, techniques for microstructural control using thermal analysis, tooling for brake rotor castings using group technology, trends in die casting research and development, shot sleeve dynamics, and applications of shot sleeve research.

Other areas of emphasis include research and development in shot sleeve life and electro-chemical polishing of die inserts, automated die polishing, die manufacturing methods influence on die life, thermal analysis for the process control of thin section gray iron castings, effects of sand and carbon fiber additions on plaster mold and casting properties, applying delta t measurements to gray iron inoculation, and improving the properties of plaster molds and castings.

Has conducted numerous studies in areas including experimental determination of slow shot velocity-position profile to minimize air entrapment, computer aided engineering of tooling for castings, effects of vacuum assist on cold chamber, high pressure, die casting, computer modeling for improving the life of cold chamber shot sleeves, computer simulation of thermoelastic deformations in horizontal cold chamber die casting machine shot sleeves, automated die and mold finishing, and short stroke honing.

Knowledgeable in areas including prototyping for injection molding using laminate tooling, modeling fluid flow in horizontal cold chamber die casting shot sleeves, minimization of entrained gas porosity in aluminum horizontal cold chamber die castings, vacuum assisted die casting, evaluation of the fatigue behavior, evaluating the quality of vacuum die castings, and optimal slow shot profiles for cold chamber die casting.

Other areas of interest include analysis of the effects of die casting process control on casting dimensional variability, analysis of mechanical failures in shot sleeves, alloy cooling and solidification in horizontal cold chamber die casting machine shot sleeves, control of microstructures in die casting aluminum alloys, concurrent engineering of die casting process parameters and tooling

PRINCIPAL INDUSTRIES SERVED
Metallurgical, Manufacturing

EDUCATION
Ph.D., Industrial and Management Systems Engineering, Penn State University
M.S., Metallurgical Engineering, The University of Michigan
B.S., Metallurgical Engineering, Western Michigan, Magna Cum Laude

PROFESSIONAL EXPERIENCE
Consultant, Kevin Kennedy & Associates, Inc.

Providing industrial and management systems engineering, metallurgical engineering, manufacturing process, materials, and metals processing consulting, forensic engineering and related expertise to a wide variety of clients.

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Professor of Industrial Engineering, Ohio State University

Graduate research assistant, Penn State University

Worked as a GRA on a General Motors Technical Center project regarding the effect of high aluminum content charges in the cupola melting of gray cast irons. Conducted research regarding rapid prototyping for die castings using the plaster mold process for Erie Bronze and Aluminum Corporation. Developed a group technology scheme for the General Electric Corporation at their Appliance Park facilities in Louisville, Kentucky. Developed a PC based group technology and computer aided engineering system for Iroquois Tool Systems, an aftermarket supplier of automotive brake components

Instructor, Muskegon Community College, Muskegon, MI

Taught materials science, metallurgy, casting, welding, and physics for Department of Manufacturing and Techology.

Corporate metallurgist, Sealed Power Corporation, Muskegon, MI

Responsible for process development and quality engineering for gray, ductile and malleable iron foundries manufacturing of automotive piston rings, cylinder sleeves, valve lifters and camshafts. Conducted failure analysis of dynamometer tested, racing, and customer returned engine components. Conducted research and development of a recycleable shell system for the investment casting foundry producing stainless steel propellers and pre-combustion chambers for General Motors diesel engines.

ADDITIONAL EXPERIENCE

CONSULTING EXPERIENCE
Lexpert, RANCO North America, Thompson, Hine & Flory, AMTEX Corporation, ARC Industries, Weiner and Suit Co., Attorneys at Law, KalKan Corporation, Vining Corporation, Honda of America, Echo Corporation, VICO Products, Vining Corporation, McLanahan Corporation

PROFESSIONAL REGISTRATION
Registered professional engineer, State of Ohio

PROFESSIONAL AFFILIATIONS
American Society of Engineering Education (ASEE)
North American Die Casting Association (NADCA)
Society of Manufacturing Engineers (SME)
The Metals Society (TMS)

PUBLICATIONS
Numerous publications and invited presentations related to manufacturing processes, materials, metals processing and the design and manufacture of dies and molds for forging, extrusion, permanent mold and pressure die casting, stamping and press forming, rapid prototyping for die castings using the plaster mold process, group technology and computer aided engineering systems.

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

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Case Studies

Industrial and Management Systems Engineer, Metallurgical Engineer, Manufacturing Process, Materials, and Metals Processing Consultant, Accident Investigation, Accident Reconstruction, Specialist, Forensic Analysis, Investigation, Product Liability, Expert Witness Testimony, Engineering Consulting Services
Resume of ALD metallurgist, foundry consultant, cast metals consultant, engineering failure analysis, accident investigation, accident reconstruction, specialist, forensic analysis investigation 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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