Resume - Senior Weld Mgr / Engineer. I have for decades specialized in providing manageme...

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Resume #82193

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USA / Canadian / UK Passports.

Education:
City Guilds. Stretford Tech College. UK. 1967: Welding / Metallurgy.
Canadian Welding Institute. Welding Principles Practices. Program.
Canadian Welding Institute. Weld Quality / NDT. I taught this course.
Linde / Union Carbide Training. Automated MIG / TIG. Training Program
Canadian Weld Institute. Aluminum MIG / TIG I taught this course.
University of Wisconsin Dept of Engineering. Weld Technology / Weld Metallurgy. Course.
Ohio State University. Robotics and Arc Welding. Course.
J W Thermal Dynamics. Advanced Plasma Weld / Cutting Course.
MK Products. Orbital, GTAW Tube and Pipe Welding Course.

Since May 1998 to present. WeldTrain International. Asheville, North Carolina.

Position: Senior Weld Mgr / Engineer. I have for decades specialized in providing management support for the implementation of Best Weld Practices and the establishment of Weld Process Controls. I have managed welding projects on pipe lines, nuclear plants, power plants, waste energy plants, ship yards, bridge construction and structural steel shops. I have optimized weld quality and productivity in hundreds of weld shops and developed unique process control training programs with the MIG / Flux Cored / TIG / SAW / SMAW processes

Diversity, Weld Automation and Process Expertise: My thirty five plus years focus on providing unique, simplified weld process control training methods along with my extensive robot / automation expertise, enable me to instantly provide optimum weld quality and productivity on any complex applications. I have set robots to pulsed MIG / flux cored gas / oil pipe lines and pressure vessels. I set the world's first robot pipe welds and set robot welds for pipe casings on an Alberta oil rig. I set robots and developed patents for automated weld systems to overlay Inconel and stainless on boiler water wall pipes. I developed unique systems and procedures to overlay pressure vessels, ID pipe and valves welds. I established the robot welds for the world's largest trucks made by Caterpillar. I also set the robot welds for the world's biggest selling trucks, Ford FI50 and set the robot welds for today's Harley bike frames and the new Corvette..

I have extensive expertise with the MIG, TIG, FLUX CORED, PLASMA, LASER / HYBRID and SAW. I have advised over 1000 companies in 12 countries on methods for process optimization / continuous improvement in weld productivity, quality, and safety. My fabrication and welding expertise covers forming, manufacturing, material handling, cutting, ferrous and none ferrous, pipe, plate, structural, cladding, pressure vessels. Proficient in the following codes / standards. ASME Sections I, II parts A/B/C/D, V, VIII (Div. 1 and 2), IX, ASME B31.1 And B31.3. AWS D1.1, NBIC, ASNT, API 510, API 570, API 579 / NACE and other weld codes / specifications.

As a key committee member during the last decade, I developed American Weld Society (AWS). MIG Specifications and was an advisor for the AWS Flux Cored Specifications. I am responsible for the development and introduction of four of the top 10 MIG gases used in North America. I was the author of the "Thermal Cutting Section" on Laser-Plasma-Oxy Fuel Cutting in the ASM Handbook Ninth Edition 1988. I wrote the complete Welding section for "Machinery Handbook" 25th edition. I have had 40 weld articles published on weld process controls and best weld practices and have also written three books on the subject. I have developed and sell unique MIG and flux cored Process Control Training programs for both manual / robot welds.

.

2009: Most recent employment. Cameron Houston USA / Leeds UK. Cameron is a global manufacturer of Sub Sea / Onshore / Refining Valves and components. Hired on a contract basis to deliver root cause analysis and weld resolutions for sub sea valves, with automated, TIG, Inconel clad weld issues that were resulting in extensive weld / machining rework. Provide the solutions to reduce weld defects from 9 to 1 % and established best weld practices and a process control training program.

2007-08 Welding Services (WSI) Atlanta. Georgia. I was hired as a contract weld manager. WSI has been responsible for more than 80% of the Inconel and stainless boiler water wall overlay projects in North America. I established a new Inconel and stainless automated MIG cladding method for boiler water wall overlay. This method was patented in 2007, My clad patent dramatically improved the water wall clad weld quality and reduced the costly clad consumable costs by 28%..

In 2008, one of my consulting positions was weld manager with North American, GE Quality Council. I provided Six Sigma process quality and productivity improvements to to plants in Mexico Canada USS and Puerto Rico. In the last few years I worked on welding optimization projects for / Imperial Oil / General Dynamics / GE Railcar / ABB / WSI / Magnatech / BOA / Flexonics / GM / Dana / Textron / Honda/ Toyota / Tower / Milton Bridge / Manitowoc Cranes / Holland Manufacturing / Astec / Graco Inc. / Aker Ship Yard. PA.

Expertise:
ƒá 35 plus years expertise in establishing process controls with manual / automated GTAW / PLASMA/. LASER Tubemills, Turbine Repairs, Orbital welds, Micro alloy applications and automated pipe / valve welds in industries such as: nuclear, power, aerospace, medical, electronic, power, oil, refinery and chemical.
ƒá 35 plus years expertise on setting optimum MIG / Pulsed MIG / Flux Cored on manual and automated pipe / pressure vessel welds.
ƒá 25 plus years expertise on establishing effective "robot" MIG weld process controls for all robots in all industries that utilize robots.
ƒá Highly experienced in all manual and mechanized MIG / GTAW / FCAW "Cladding" applications. Have three patents with these applications.
ƒá Provide estimates, quotes and recommendations for cost affective robot / automated weld lines and related weld manufacturing equipment.
ƒá Extensive metallurgical and lab expertise on weld failures, cladding, wear and weld corrosion issues.
ƒá Work with Designers to improve weldability of welded components and structures

SOME WELD ACCOMPLISHMENTS AND COST REDUCTIONS:
1. Imperial / Esso Oil, Cold Lake Alberta, Canada. Requested by Imperial Oil to provide manual and automated MIG - flux cored process control training. I trained their stick pipe welders to accept the use of the MIG / flux cored process on their pipe line and shop applications. I then trained these welders on the use of automated MIG / flux cored on steam / natural gas / oil pipes ranging from 10 to 100 cm diameters. The total annual weld savings generated from the training with the 37-field crew has been approximately
$2 million annually.
2. Provided Robot MIG Weld Process Control Training Program for Magna the world's largest tier one supplier.
3. Textron: Thailand. Managed a 6 month project and developed manual / automated MIG / flux cored weld procedures and repair techniques for weld repairs on 160 Textron Stingray Army Tanks. (275.000 tensile armor plate).
4. Combustion Engineering.
[1] I established unique "robot" pulsed MIG nickel weld procedures for overlay boiler walls.
[2] Set robots to pulsed MIG boiler headers to pipes, (typically carried out by skilled GTAW welders).
5. Aker. Philly Naval Ship Yard. Oil Tanker Construction. Introduced to the yard Best Weld Practices and developed a one day flux cored weld process control training module. Within six months, this training program reduced the ship weld rework by 50% which resulted in an approximate of cost reduction of four million dollars per ship.
6. General Dynamics Ordinance and Tactical Systems. TX. Improved the` weld quality / productivity on 2000 bomb casings.
Recent Employment Contracts:

[1] Aker: Philadelphia Naval Ship Yard:
Contract Position: Weld Manager

Established unique Flux Cored Weld Process Control Training for oil tanker construction. The yard has 300 welders. Within six months, my eight hour training program reduced the flux cored weld rework and NDT
costs per-ship by 50%. Savings per ship approx 4.5 million dollars.

Also established Best Weld Practices for Aker ship yard reducing annual weld equipment / consumable costs by $500,000.

[2] Viza: Vigo, Spain

Viza makes auto / truck seats for Toyota, Renault, Citroen, BMW and others. I established Best Weld Practices / Robot Process Controls and the robot MIG welding training programs for this organization during it's start up of two plants, one Spain and the other in Checkoslovakia.

[3] Kolberg / Astec:

Rock crushing equipment, feeders, screens, sand classifying systems, aggregate conveyors, asphalt and pug mill plants. Provide manual and robot weld solutions to weld cracking problems and provided MIG / FCAW weld process for over 400 welders and engineers.

[4] From Jan 2006 to Jan 2007
Welding Services Inc. (WSI)
Atlanta, GA
Contract Position: Weld Manager

This company has approx 400 field welders that provide repairs in global Nuclear / power plants. They also were the leaders is supplying automated weld overlay on boiler water walls as used throughout the waste management, and power industry. WSI uses approx. one million pounds of Inconel annually. This company has been responsible for stainless and Inconel cladding on more than 80% of the water wall boilers in North America. I was hired on a contract basis with the following responsibility;

[] Provide support in WSI's development and implementation of WSI'S welding program for qualification of personnel, procedures, and processes.
[] Provide support for weld / metallurgical shop and field issues.
[] Provide support for issues / questions regarding interpretation, application, and intent of Codes and Standards governing welding and inspection activities and specific customer specifications.
[] Responsible for all weld research and development, product development, and technical support initiatives for continued improvement of WSI products and services.
[] Provide cost-effective resolutions consistent with company strengths.
[] Supervise development and implementation of the training program for WSI weld personnel.
[] Interface with customer Quality Control / Quality Assurance personnel to provide direction on issues related to welding quality. Interface with Authorized Inspectors to explain / resolve issues related to governing Codes and Standards.
[] Assist in evaluating new materials and weld equipment for clad and weld applications. Evaluate metallurgical and welding characteristics and perform testing to assess potential benefits.

[] WSI: I developed new water wall, Inconel / Stainless clad procedures that were patented by WSI in 2006-7. My new pulsed MIG procedures and techniques reduced by 28% the typical amount of Inconel or stainless cladding consumables required per-square foot of coverage of water wall boiler tubes. This patent will eventually produce an annual cost saving for WSI of approximately 6 million dollars and the superior pulsed MIG over lay weld quality will provide many benefits such as improved corrosion resistance and less distortion.

[] WSI: I provided unique pulsed MIG pipe procedures for 9 ¡V 36% Nickel Cryogenic applications.

[] WSI:. I developed a patent pending, highly cost effective weld technique for 347 overlay on hydro cracking vessels and other 347 clad applications. This new 347 clad method reduced the traditional global electro slag, strip clad methods cost for overlay by 70%

That same year, I also developed a new method for attaching boiler wall insulation brackets. Rather than attaching studs for the brackets, I developed a unique MIG spot weld process which eliminating the studs. The cost of the operation was dramatically reduced. This process was also patented.

Company. MKS Instruments, Inc. MA.
12 month employment contract:
Position: Weld Manager.

Established Weld Best Practices and weld cost reduction programs for automated, laser / GTAW / plasma, lathe and orbital welds on stainless and Inconel components. These monitoring parts were used in the manufacture of electronic chips. Established over 2 million dollars in weld cost reduction and took weld reject rate from 8% to less than 1 percent.

Company: Textron / Omniquip. Port Washington, WI
2000 to 2002
Contract Position: Weld Manager: Heavy Fabrication

Scope: Hired to reorganize the weld department, establish best weld practices, provide substantial weld cost reductions and increase the MIG weld automation. Responsible for approximately 120 welders. The product was heavy-duty steel frames and booms used for construction lifting equipment.
* In the 15 months at Textron / Omniquip, I increased utilization of arc welding robots from 8% to 80%. providing an 80% increase in the welded parts produced with no increase in manual labor.
* Facilitated and implemented effective robot and manual weld process controls along with weld process-training programs, resulting in a daily robot weld efficiency of > 96%
* Reduced the three weld vendors to one and established a "weld blanket purchase agreement" resulting in $200,000 annual savings.
* Established highly cost effective "best weld practices". Reducing annual equipment and consumables cost by $250,000.
* Produced the weld department budget.
* Provide support and developed the training programs for weld safety, weld quality, weld productivity.

1998 - 2000 Consulting. WeldTrain. (My Consult Company)
Wilmington, NC:
Weld Process Improvements at companies listed above.

Company: ABB Flexible Automation.
Division: Robotics, Welding and Cutting.
Position: Weld Process Manager.
1994 ¡V 1998.

Hired as North American weld guru for the ABB Customer Service Div. My responsibilities was to resolve robot weld quality / productivity issues for North American clients.

Company: Airgas, Inc. USA. 3 yrs.
Position: Weld Marketing / Weld Training Manager.

Airgas is the world's largest independent welding distributor. I was employed by Mr. Mc.Ausland. the company owner to develop MIG weld gas / weld equipment sales strategy that would give Airgas a distinct Franchise look to its Industrial gases and welding equipment business. In eighteen months through my marketing program that simplified MIG gas selection, I introduced three gas mixes, (SteelMix ¡V StainMix ¡V AlumMix). With this program and the technical sales training I provided, Airgas increased its annual new MIG gas business by 60 million dollars. At Airgas, I also provided weld / cutting process training for the 700 sales reps and provided weld process advice and solutions for hundreds of weld customers across USA and Canada.

Note: Four multi-purpose MIG gas mixes that I developed for MIG welding steels, stainless and nickel steels are now common MIG gas mixes sold throughout North America.

Company AGA. Gas. Cleveland. OH. 3 yrs.
Position Weld Equipment Product / Training Mgr.

Same job description as Airgas.

Company Union Carbide Linde, Canada 4 yrs.
Nuclear Power and Cryogenics Div.
Position: Weld Department Manager

Managed the weld fabrication of heavy alloy, stainless and aluminum components used for Canada's Cryogenic, Heavy Water and Nuclear industries. Responsible for all welding quality, productivity, weld procedures, weld qualifications, weld code compliance for more than 140 welders using GMAW- FCAW ¡V SMAW - SAW - PLASMA ¡V RESISTANCE. Worked with ASME, ANSI and API codes.

Transferred from Union Carbide to sister company Linde Weld Distribution Division, Canada as the Linde West Coast Weld Training Manager. Provided weld / cutting process training and advice on weld issues to hundreds of customers and to Linde weld distributors.

Company: Atomic Energy Nuclear Research. Ontario. Canada 4 yrs.
Position: Weld Technologist.

In the Nuclear research department, I worked with alloy steels, stainless, aluminum and titanium pipes and tubes and valves, providing weld / clad and cutting research. Developed new weld / clad repair procedures for Pickering Nuclear plant and for the Bruce Heavy water plant.

Company: Weld Institute. Canada. 3 yrs:
Position. Weld Research Technologist.

Numerous weld research and weld test studies for major Canadian, USA corporations. Weld failures / corrosion / erosion / wear analysis for Canadian / USA companies.

Shawinigan Engineering. Canada. 4 yrs.
Position: Weld Quality Control Manager.

For two years worked in Sapele. Nigeria. Position: Weld Quality Engineering Mgr. Responsible for welding quality during construction of Africa's largest oil /gas power station. Provided global Inspection on US / Canadian Nuclear / power plant components, turbines, pumps, compressors, valves etc.

Ontario Hydro. Canada 3 years.
Position: Quality Control Supervisor.
Project: Construction of the Canadian Bruce Heavy Water and Nuclear Plant.

Experiences and Achievements:
Provided GMAW / FCAW / SAW / PLASMA / GTAW / SMAW / LASER / OXY FUEL training for over 10,000 weld decision markers in ten countries. Have extensive welding application background in all major welding industries. Automotive, Ship Yards, Chemical Plants, Pipe and Pressure Vessels Shops, Structural Shops, Nuclear and Research. Optimized robot weld productivity using ABB - Motorman - Panasonic - Fanuc - ESAB - Cloos, and Miller robots. Computer skills, MS Word, Word Perfect, Power Point, Web Page Management using Dream Weaver.

Committees Columns, Books and Articles Published:

ƒá In 1998 as an AWS specification committee member, I completed for the American Weld Society the new
AWS MIG, / TIG, Plasma Welding Shielding Gas Specifications.
ƒá Developed and introduced four of biggest selling MIG gas mixes in North America.
ƒá 2001 AWS subcommittee advisor on the AWS specifications for Flux Cored Electrodes.
ƒá Developed the "PocketWelder" the world's first hand size, electronic weld data / steels unit. Sold by AWS.
ƒá For 15 years, I advised over 50,000 readers in the Question Answer Weld Column in Weld Design Fabrication Magazine.
ƒá Published over 35 welding / cutting process control articles.
ƒá Rewrote the Thermal Cutting Section" on Laser-Plasma-Oxy Fuel Cutting in the ASM Handbook Ninth Edition 1988.
ƒá Wrote the complete welding section for "Machinery Handbook" - 25th edition.
ƒá In 1991 wrote and published welding book "Gas Metal Arc & Flux Cord Welding Parameter Selection Made Simple", sold through AWS.
ƒá In 1992 produced a MIG training video "MIG Training Made Simple" sold by AWS and Fabricator magazine.
ƒá In 1996 wrote the 600 page book "A Management & Engineers Guide to MIG Welding, Quality, Costs and Training".

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