Quality Manufacturing
Resume:
Vancouver, WA *****
abng9w@r.postjobfree.com
RESUME OF DANIEL R. CADY
SUMMARY OF QUALIFICATIONS
Expertise in evaluating, developing and delivering new materials and processes f or engineering applications
Extensive experience leading product/process development projects using a stage gate program
Extensive knowledge of coatings, adhesive systems, elastomers, sealants and related polymer-based materials
Hands-on formulation of coatings, hot melts, adhesives, sealants, water and solvent based systems
W ide array of experience with nonwovens, woven textiles, knit fabrics, films, glass, metal and polymer substrates
Experience developing, managing and implementing quality systems per ISO 9001
Hands-on, cradle-to-grave development experience including R&D, plant trials, scale up and process optimization
Extensive experience providing technical service to manufacturing plants f or materials and process related matters
Demonstrated ability to deliver innovative commercial products and associated manufacturing processes
Demonstrated innovation through delivery of intellectual property and novel approaches to problem solving
Demonstrated ability to manage, train, motivate, supervise and mentor staff
Advanced skills in communication, team building, collaboration and project management
Senior R&D Chemist/Quality Manager ICD High Performance Coatings, Vancouver, WA 2008 to 2009 (laid off)
Investigate, procure and implement new technologies for coatings/paints used in architectural applications
Coatings formulation of silicone, epoxy, vinyl based systems including pigment dispersions and base formulas
Manage materials compatibility program to ensure product life and suitability for use in severe environments
Coordinate materials compatibility program with internal and external customers via database management
Evaluate coatings for UV resistance, color stability, field durability and contact with adjoining materials
Monitor materials changes via testing with QUV, UV, Weather-O-Meter, environmental chambers, ovens/baths
Conduct physical and chemical tests on adhesives, coatings, base resins and finished materials
Develop peel and adhesion tests for customer based substrates with new/existing coatings/paints
Develop and implement new technologies to improve adhesi on to multiple substrates
Source and procure test and process equipment for research and manufacturing departments
Develop new process methods, improve existing manufacturing practices, write/implement associated procedures
Improve quality practices in dispersion, batch making, color matching/correction and quality assurance depts
Develop methods and source equipment to increase surface energy of substrates to improve bonding
Transfer technology from R&D and scale into manufacturing ready processes
Collaborate with vendors to improve raw material product quality and introduce new material technologies
Ensure quality of incoming and outgoing materials and finished products meet internal and industry standards
Manage/supervise and mentor quality technicians, lab technicians and manufacturing personnel
Revamp existing quality department and bring into compliance with ISO9001/updating QMS system and manual
Oversee calibration and maintenance of analytical tools and equipment used in plant and labs
Senior Materials Engineer Cummins Filtration, Stoughton WI 2006 – 2008
Responsible for polymer and nonwovens materials development in multiple product lines. Led program development efforts
through a stage gate process. Created patented technologies using innovative designs and unique implementation of
materials and processes. Developed techniques to clean and modify surfaces to enhance bonding and improve product
durability in the field. Engineered materials include: UV inks, adhesives, hot melts, coatings, elastomers, nonwovens and
various polymers.
Materials development for simultaneous product line introductions. Coordinated efforts with cross-functional teams
including supply chain, manufacturing, engineering, quality and lab sciences
Participated and lead DFEMA, PFEMA, SQI and APQP activities through Value Product Introduction (VPI) process
Developed new materials technologies that lead to the creation of intellectual property
Provided technical service and engineering support to 8 plants to resolve, coating, adhesive and polymer issues
Collaborated with engineering to ensure a working product was delivered along with process solutions for the
manufacture of new products
Investigated, sourced and approved new and improved materials per engineering and ISO quality initiatives
Developed nanofiber nonwoven composites for air filtration applications
R&D Materials Engineer Habasit ABT, Inc., Middletown, CT 2002 to 2006
Responsible for the formulation and development of polymeric coatings for new market segments for Industrial Belting Group.
Optimized chemical and physical properties, developed and improved adhesive bonding methods, lamination processes, enhanced
surface preparation techniques and maximized processability. Altered and enhanced material properties to meet customer
specifications. Engineered materials include: polyurethane adhesives, polyurethane coatings, rubber and plastic primers, rubber
substrates, silicone elastomers, adhesive films, timing belts, woven fabrics, knit fabrics and pressure sensitive adhesives
Opened new markets for Habasit ABT, Inc. by creating commercially viable products. Sales and marketing estimate
annual revenues of new products to grow to several million dollars in sales two years
On-going technical enhancements increased product life by a factor of 2X over competitors. Increased product
durability and field performance
Created and developed manufacturing processes (SOP’s and work instructions) for transfer into production f acilities
Recommended, sourced and purchased molds, tooling, meter mix and dispense equipment, spray equipment,
coating equipment and peripheral equipment
Assisted in setting up production facilities and transferred all product knowledge to applications engineering
Trained production personnel
Developed continuous improvement measures to optimize processes, minimize waste, increase yield and reduce
material use
Developed and lead quality measures per ISO9001. Established internal protocols using SPC and quality tools
Materials Engineering T echnical Lab Manager Cummins Filtration, Stoughton, WI 1999 to 2002
Developed and implemented new materials into advanced products and engineering processes. Developed products using
innovative technologies and design concepts. Supported manufacturing activities of 8 plants that produce OEM and
aftermarket products for the automotive, military, construction, agriculture, marine and mining industries.
W orking Project/Materials Lab Manager: Supervised and directed R&D materials development activities and project
work for a group of chemical engineers, chemists and laboratory technicians
Developed polymeric materials such as fiber surface treatments, coatings, laminating films, adhesive potting
compounds, polyurethane seals, elastomers and related materials
Developed polymer/synthetic media for liquid and air filter products to meet and exceed OEM customer expectations
Acted as a technical liaison between materials suppliers and engineering department
Made product recommendations/presentations to internal and external customers
Conducted manufacturing/plant trials of various materials and processes
Provided technical service to plants to assist with bonding issues and adhesive applications
Developed test methods, SOP’s and materials specifications per internal, ISO and QS9000 standards
Responsible for lab management, budget, capital expenditures, equipment calibration and maintenance
Conducted training and development of laboratory and production personnel
.
Lab Tech/Materials Chemist/Senior Materials Chemist Cummins Filtration., Stoughton, WI 1987 - 1998
Development, evaluation and recommendation of various types of materials used in filtration and acoustic products
Responsible for the development of thermal inks, UV inks, adhesives, polymers, nonwovens and related materials
Improved cost and performance of various types of coatings, adhesives, PSA’s, epoxies, cyanoacrylates, anaerobics,
plastisols, UV curables and water-based systems
Performed analyses on materials to determine physical properties and performance characteristics
Conducted failure analyses. Suggested/implemented corrective actions for improvement
Introduced new technologies and advanced processes into production facilities
Developed nonwoven composite formulations using glass, cellulose and synthetic fibers
Replaced materials with superior products at reduced costs, saving over $500K annually.
ISO/QS9000 coordinator/librarian for Materials Technical Laboratory
Implemented a wide array of advanced coatings, adhesives and related processes. Improvements included
enhanced bonding, chemical resistance, durability, superior mold release characteristics, improved processing
performance and excellent physical properties.
Core Skills
Team leader, team player
Ability to work effectively with a diverse group of people at all levels
Highly adept at managing people, projects and products in an organized manner
Strong degree of technical adaptability, flexibility and a keen interest in learning new skill sets
Independent thinker, self-starter, highly motivated and self-reliant worker
Effective oral and written communication skills
Strong sense of urgency, ability to meet project deadlines and budgetary requirements
Proficient with various types of software including Excel, Word, Power Point, Lotus Notes and Internet search tools
Analytical/Technical Skills
Capable of performing various types of analyses on chemical and physical instrumentation using: SEM with X-ray, optical
microscopy, tensile (Instron) testers, FTIR, GC, AA, UV-VIS, rheometers, viscometers, spectrographic analysis, particle size
analyzers, multi-pass and single pass testers, environmental chambers, hardness testers, viscometers, density meters,
TAN/TBN and KF titrators as well as many other types of laboratory equipment. Adept at reading technical drawings. Can
use various types of software to review data, design experiments (DOE) and perform statistical analyses. Attended Green
Belt training to learn Six Sigma tools, Minitab and related software.
Education
University of Wisconsin-Stevens Point, Stevens Point, WI 1982 - 1986
BS Chemistry – American Chemical Society certified degree, Minor: Mathematics
Fox Valley Technical College, Appleton, WI, AA Pulp and Paper Chemical Technology 1980 - 1982
Patents
Awarded 3 US patents Nos. 6,422,395; 6,387,144 and 6,378,706 for joint development work on intellectual property for new
products, materials, concepts and technology advancements. Have completed 3 additional patent applications for flexible
elastomeric seal, surface property conversions and new sensor technologies
Professional Associations (past and present)
American Chemical Society, ASM (The Materials Information Society), Society of Automotive Engineers, Technical
Association of the Pulp and Paper Industry, American Filtration and Separat ions Society, National Air Filtration Association,
Society of the Plastics Industry, American Society of Mechanical Engineers
Examples of Project Work:
Proactive delivery of improved manufacturing processes and development of polymeric materials for OEM and aftermarket
products. Managed cradle-to-grave projects from concept to product introduction including lab evaluation, process trials,
prototyping and final implementation into the manufacturing environment. Provided technical service to several
manuf acturing sites. Examples include:
Formulated new line of coatings products for introduction into new market segments. Worked directly with
customers, supply chain, sales, marketing, quality, engineering and production to follow product from concept int o
commercialization. Made continuous improvements per customer requirements
Acted as internal company expert on polymeric related matters. Recommended products and processes, conducted
field trials, failure analyses and analytical testing. Acted as liaison between engineering department, outside vendors
and customers
Developed polymers and films to bond a wide variety of substrates including fabrics, metals, plastics, rubber,
ceramics, glass and cellulose based materials using a wide array of adhesive and primer based systems
Implemented thermal lamination process to join various types of rubber timing belts to elastomeric polyurethane
overlay
Developed new primer systems for improved adhesion to several types of substrates. Increased bond strength by
ten-fold whereby the substrate failed before the adhesive bond
Developed new methods to improve surface energies for enhanced chemical bond via corona and plasma
technologies. This advancement enabled design engineers to permanently join two dissimilar materials such as
polyolefins and metals. Opened the door for engineers to utilize a wider selection of products in their design
W orked jointly with vendors to develop unique formulations of elastomeric materials for sealants and encapsulants.
Collaboration yielded desired physical properties including: compression set, tear, tensile, elongation, chemical
resistance, durability, flame retardancy, heat aging and mold resistance
Continuously investigated new methods of streamlining processes to reduce manufacturing costs while making
materials more user and production friendly. Improved the “green” rating of materials to comply with EPA, OSHA as
well as federal and state mandates
Introduced UV technologies into production facilities for several families of materials. Invisible dyes (only detected by
UV light) replaced conventional visible light materials greatly improving the aesthetic quality and customer perception
of the finished product. Light curing adhesives greatly reduced process times
Replaced convection cured silkscreen inks and coatings with ultra fast curing UV materials slashing production time
by over 80%. Chemically resistant UV sealants were developed to resolve manufacturing problems that could not be
overcome with standard line adhesives and processes
Developed improved versions of several types of adhesive and mold release plastisols. Some improvements
included enhanced chemical resistance, improved adhesion to a variety of substrates, excellent mold release
characteristics and superior physical properties.
Developed lower cost versions of polyamide hot melts for manufacturing operations. Improved hot tensile, green
strength processing speed and sealing problems. Reduced material costs by over $500,000 per year.
Introduced new cyanoacrylates to improve process and bonding related problems in manufacturing facilities.
Process related problems were reduced to zero occurrence and material costs were reduced by over $50/pound.
Developed and introduced many other materials and processes including structural epoxies and polyurethanes, EVA
hot melts for product manufacturing; anaerobic methacrylates for press fit and crimped assemblies, plastisols and
silicones for extreme temperature and environment uses.
Combined improvements and cost savings exceed 2 million dollars
General Equipment and Materials Knowledge:
Dispensing equipment: specified, recommended and purchased dispensing and process related equipment for one and
two part adhesive systems for meter mixing, dispensing, spraying and related applications. Assisted in automating
production lines with new equipment and robotic dispense heads via collaboration with manufacturing engineering
General Process equipment: laminators, roll coaters, spray coaters, curing chambers, drying ovens, UV detectors, corona
and plasma treaters, homogenizers, mixers, ball mills and material applicators
Hot melts: polyamide, polyurethane, EVA, PVA, PVOH polyester formulations used for sealing, separation, encapsulation
and bonding of cellulose/paperboard, plastic, glass and metal substrates
Polymer films: adhesive films for bonding dissimilar substrates such as rubber and plastics as well as lamination films for
joining glass panels and web adhesives for joining nonwovens to various substrates
Polyurethanes: soft flexible foamed systems to rigid casting and potting materials used for adhesion, gasketing, sealing,
encapsulation, molding and general bonding of product components
Silicones: in the form of soft and hard coatings, adhesives, rubbers and elastomers for gasketing, sealing and encapsulating
a wide array of materials including architectural glass, polymers and metals
Plastisols: adhesive, mold release, mechanical and chemical foamed materials for molding, potting, casting and coating of
various production materials
Epoxies: one and two part systems, conductive, non-conductive used for bonding, potting, sealing, coating, casting and
encapsulation of paper, plastic, metal, heating elements, electronic components and nonwoven materials.
Plastics: Thermoplastic resins for product housings, element cores, prototype castings and melt blown nonwovens including
PP, PET, PPS, PVC, PTFE and PA
Rubber: neoprene, EPDM, silicone, polyurethane, natural and nitrile rubbers for o-rings, gaskets, grommets, belt covers
Inks and dyes: water and solvent based inks/coatings for logos, decals, and product ID. UV dyes for invisible marking for
processing to enhance aesthetic quality of product
UV Sealant: UV cured polyurethane sealants for potting and sealing complex media shapes in filter assemblies
PSA’s and Acrylics: adhesives for rubber, cellulose, cork, fiber gaskets, labels, and nameplates
Cyanoacrylates: “instant” adhesives for bonding rubber, metals, plastics and a variety of other materials f or product
attachment
Anaerobics: methyacrylate based materials for thread locking, sealing, gasketing, and retaining of nuts, bolts, crimped
seams and press fits metal assemblies
Solvent based adhesives: rubber based nitrile phenolics for lamination and bonding of gaskets, filtration media, wire screen
and nonwovens
Water based adhesives: sealing, bonding and side seal adhesives for cellulose based filtration media and fiber based
gaskets
Ceramics: high temperature ceramic sealants for catalytic silencers
Related Products: mold release agents, lubricants, cleaners, degreasers, anti static agents and other anti -
corrosive/protective coatings.
Nonwovens: made from natural and synthetic fibers that are spun bond, melt blown, wet laid; dry laid, carded and needle
punched (as well as knit and woven fabrics)
Paper Based Products: f or a wide variety of applications including paperboard side panels, labels, ID tags, decals and
related applications
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