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Staff Chemist

Hixson, TN, 37343
April 01, 2021

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Robert N. Wilson

Summary of Qualifications

An Experienced Business Leader and polymer foam expert with a successful track of introducing strategic change and turning around business performance in large global corporations. A highly intelligent and strong leader with excellent communication skills and the proven ability to set direction, move a complex organization quickly to execution and deliver step-change improvements.

Professional Experience

Consulting – Production programs and International business development specializing in new market entry and business expansion for domestic and offshore manufacturing companies. The startup of new polymer industries and the improvement of efficiency of existing processes.

Motus Integrated Technology – Detroit, MI (Office), Holland, MI (1 plant) and Mexico (3 plants) Polymer Expert September 2018 – January 2020

Requested to lead the development of box poured foam in Holland and improvements of molding lines in Mexico. Also, develop a processing standard for prototype molding in Holland. Took over the development work in the Detroit facility. 3 projects completed during the first year that is saving $470K per year.

INOAC – Michigan Senior Account Manager April 2016 – May 2018

Requested to join INOAC to increase sales of Technical foams. Doubled sales in the first year. Assisted the R&D group in the development of new products.

Woodbridge Foam Partner - Chattanooga, TN Senior Account Manager November 2014 – January 2016

Requested by executive management to return by management. Previous Sales after starting the new Joint Venture ranged from $200K to $400K, per month, with the new customers. During my absents sales had dropped to around $2K per customer, per month. Returned and brought the sales numbers back to my original numbers .

Tempur + Sealy – Duffield, VA Senior Technical Manager March 2011 – November 2014

Improved manufacturing processes from 78% to 98.5% in the first year. Lead cost savings projects that saved $8M in the first 3 years. Designed and implemented equipment that reduced customer rejects by (96%), organized working areas, improved product quality and production processes. Built strong teams. Well trained and cross trained with strong leaders.

Gill Industries – Trenton, GA PU plant Manager 2009 - 2011 PU Plant Manager Responsible for the startup of a new HR molded operation. Installation and debugging of new processes, with new product introduction. Manage all aspects of a new production lines and new Chemistry. Build strong Teams for the operation. Established Safety, Environmental, Quality and Production standards and requirements.


Senior Accounts Manager, Woodbridge FoamPartner, Chattanooga, TN (2006-2009). Start up new joint venture for Technical and Reticulated PU products. First year $5M in sales. Increased sales in the second year $2M, increased customer base and introduced new products. Provided Technical assistance during equipment installation and reticulated foam production. Fulfilled General Manager responsibilities during an 8-month period until a GM was hired.

Program Manager, Woodbridge, Troy, MI (2003-2006). Responsible for $10M in sales. Headliner, Body Cloth, Technical foams and molded seats. These sales are from 4 facilities; Addison, Atlanta, Chattanooga and Greensboro. Increased sales by more than $1M of new business.

Account Manager, Dynaflex, Addison, IL (1999-2003). Increased sales by more than $3M. Molded Truck seating and Executive office chairs. Attracted new customer and awarded $500K in new business. Second Truck seat business. Assumed responsibilities for QA Manager; passed 3 QS Audits. Decrease rejects by 98%. Fulfilled Plant Manager responsibilities during a 4-month period until a Plant Manager was available.

Technology Manager, Woodbridge, Chattanooga, TN (1997-2000) Established a system for identifying and monitoring efficiencies of chemical conversions and yields. Implemented measures to improve efficiencies. Improved yields from 63.5% to 90.5%. Initiated a continuous process improvement program for machine and man reliability and diminished variability. Established initial SPC measurables and procedures and pre-production inspection.

Improved meantime between failures from 2hrs. to 5.6hrs. using Pareto Analysis (based on the average 24hr./month machine run time). Initiated scrap studies to determine the “source areas”. Reduced scrap of one product line by 90% over FY97 ($270K). Scrap reduced over all product lines by 7%. Resolved various product-processing issues. Successfully transitioned three new raw materials to save/avoid cost increases of over $100K. Resolved OSHA and TSCA issues that arose concerning new raw material introductions and imported chemicals for production. Fulfilled Plant Manager responsibilities during a 6-month period. Responsible for all EPA, DOT, and Air Pollution Control monitoring, reporting and permitting. Working with the Sales/Marketing team – Introduced 27 new products in FY98 and 28 in FY99. Collaborated with R&D to produce an in situ non-yellowing product for personnel hygiene products. Reduced Customer rejects by 95% over one year (FY1998). Completed DOE’s at customer sites that reduced rejects and improved customer’s relations. Passed 2 ISO9000 audits. Converted all paper to an electronic manual.

New Product Development Manager, (1993-1997). Development of new products from chemistry to customer follow-up. Developed a new “soft seam” adhesive technology. Facilitated Toxicological testing for personnel hygiene products. Managed the R&D facility.

Technical Manager (1989-1993). Trained and developed strong teams to monitor and improve processes, yields and products. Developed and improved the formulation systems for both production lines. Developed Low Odor polyester for personal care products. Developed several products for existing markets. Created product for the pour in place headrest and armrest market that circumvented all world patents. Worked with the legal department to trademark “Bio Free” products. Products that I developed. Responsible for all Environmental legislation concerning the site. HS&E responsibilities also included developing most policies, procedures and training for the site, OSHA, EPA, and DOT, as well as Tenn. Regs. Worked closely with Federal, State and local authorities. Facilitated the removal of Asbestos and radioactive materials from the site.

Production Manager (1986-1989). Established Standard setup/startup operating procedures. Improved chemical operation from a negative to a positive variance. Developed quality teams, initiated RFT meetings, managed chemical operations and costed all products. Developed and implemented formulation program to track formulation history, chemical usage and chemical variance. Reduced chemical usage and variance by more than 10%. Designed chemical systems and worked with Viking, Cannon, Inoac, Baumer and other suppliers to install new processing equipment. Implemented PM procedures, methods to reduce and/or eliminate off spec product, and reduce scrap. Establish the first wet lab. Developed methods and procedures for lab to full production scale.


Six Sigma Certification, Mountain Empire Community College (2012),

Sandler Sales Training (2000),

Root cause analysis, APQP, FMEA, PPAP, Kanban, 8D, Kaizen, SPC, 5S, Lean manufacturing training and Taguchi DOE.

Responsible for Team; Safety and Environmental training.

Formal Education: BS Chemistry, University of Tennessee - 1986.

Inventor listed on 6 patents issued by the U.S. Patent office and assigned to Woodbridge Foam Corp. Patent numbers; 5624971, 5817703, 5674917, 5719201, 5840780 and 5744509.

Technical Representative for Woodbridge in all communications and technology exchange with the joint venture INOAC from 1987 through 1999 and for Foam Partner from 2006 through 2009.

Responsible for all Toxicological studies on products.

Additional spoken language: Japanese.

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