International Standards ISO 9001 Auditing Consultant: Plasma Spray Ceramic Coatings

Technical Consultant #1617

Developing systems to meet the requirements of ISO 9001.
Implementing and maintaining ISO 9001 quality management systems.
Internal auditing of ISO 9001 quality management systems.
Writing effective procedures to meet the requirements of ISO 9001.
Use of statistical methods and Taguchi design of experiments.
Pack cementation processes for aluminizing, chromizing, boronizing and siliconizing.
High temperature oxidization resistant coatings, including MCrAlY (molybdenum, chrome, aluminum, yttrium) and aluminide.
Plasma spray coatings applied for wear or oxidation resistance.
Ceramic coatings on high temperature high performance turbine engine components.

Undisclosed Company, Quality Assurance Manager, 2003 - 2008

Implemented and maintained a Quality Management System to meet the requirements of ISO 9001 - 2000.
Wrote quality manual, system procedures, work instructions and forms.
Reviewed production and product databases to identify trends or opportunities for improvement.
Utilized statistical methods.
Generated PPAP (production part approval process) response documentation to the great satisfaction of a Ford sub supplier.
Knowledge of TS 16949 - 2002 automotive quality system standard and use of 8D's.
Performed internal audits and was the ISO Management Representative.
Ensured corrective actions were implemented in a timely fashion.
Established quality assurance inspection requirements and procedures for armor products.
Conducted training classes on the ISO 9001 - 2000 system and inspection and calibration procedures.
Established and maintained the calibration requirements for measurement equipment.
Co-designed a sanding fixture and developed method of use to reduce dimensional scrap and rework from 50% to 0.1%.

Alloy Surfaces Co. Inc., Chester Township, PA, Director of Quality Assurance, 1994 - 2003

Managed operations of the Quality Assurance Department, supervising 12 inspectors and 1 engineer.
Products manufactured include IR countermeasures, maskants and chemicals.
Developed, implemented and maintained ISO 9001 quality management system. Was the ISO Management Representative and lead internal auditor.
Provided technical advice and support on quality issues throughout the organization. Utilized statistical methods.
Resolved quality issues with customers and suppliers.
Estimated the cost of quality control for contract proposals and set budgets and capital expenditure levels for the QA department.
Developed improved packaging for an aircraft countermeasure. Eliminated lot failures resulting from defects caused by the original packaging.
Managed one-piece case design program to completion and great satisfaction of the customer.
Provided technical support to the countermeasures, chemical, chromate conversion, pack chromizing and aluminizing coating production operations.

Pratt & Whitney, Division of United Technologies, East Hartford, CT, 1978 - 1993

Senior Process/Materials Engineer, 1984 - 1993

Specified the functional requirements for a $1.2 million automated ceramic seal plasma spray coating system. Coordinated facility installation. Directed facility start-up and debugging.
Process engineer in charge of entire heat treat area. Production heat treating processes included carburizing, solutionizing, brazing, normalizing, austenizing, stabilizing, aging, annealing, tempering and stress relieving.
Team leader to resolve a weld cracking problem through redesign of fixtures and process adjustment, resulting in the elimination of a 50% rework rate.
Defined and implemented a plasma spray process data evaluation method for process parameters to improve part quality and reducing by 75% the quantity of test pieces reviewed.
Provided technical assistance with production fabrication of graded ceramic seals. Utilized SPC and Taguchi methods.

Senior Materials Engineer, 1978 - 1983

Developed a thin ceramic overcoating for reducing surface rumpling and improving oxidation life of NiCoCrAlY-type coatings. Used on 1st stage turbine blade on some engines.
Optimized the process parameters for a vacuum plasma sprayed NiCoCrAlYSiHf coating. Evaluation test included: burner rig oxidation, hot corrosion, tensile ductility, high and low cycle fatigue and thermal mechanical fatigue tests. This coating was selected for the 1st stage turbine blades.
Defined the effect on surface roughness, coating removal and controllability for the harperize, SWECO, abrasive slurry, glass bead peen and steel drop-peen surface finishing methods on vacuum plasma sprayed NiCoCrAlY-type coatings.
Investigated the morphology, particle size distribution, chemistry and structure of yttria stabilized zirconia powders produced by several suppliers as linked to coating performance.
Evaluated the oxidation performance of MCrAlY-type plasma sprayed and electron beam physical vapor deposited coatings. Issued final report for NASA contract (NAS3-21730).

HITEMCO, Old Bethpage, NY, Engineering Manager, 1983 - 1984

Process engineer in charge of all pack coating operations including: siliciding of molybdenum and aluminizing of nickel and cobalt base superalloys.
Developed an improved fused silicide coating for high temperature oxidation protection of columbium alloy C103. The improved coating provided twice the life of the existing coating.
Developed and production implemented a pack boriding process for coating iron and nickel base alloys.
Specified the appropriate heat treatment procedures for steels and nickel base alloys.
Provided technical production assistance for plasma spray, flame spray and wire arc coating processes.

Credentials

Short Courses: ISO 9001 Conducting Internal Audits; Principles of Lean Manufacturing; Cellular Flow Manufacturing, 5/S Visual Workplace
Process Auditing for ISO 9001:2000, STAT-A-MATRIX Institute
Internal Quality Auditing, Quality Leadership Associate
Introduction to Quality Engineering, Taguchi Design of Experiments, Pratt & Whitney
Statistical Process Control, Pratt & Whitney

Publications