Associate Consultant Bill Nelson
Bill Nelson is an injection molding expert working from Alabama
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Bill has been involved in Injection Molding since 1989 starting out as an Operator and progressed into engineering for various automotive and medical suppliers. He has been involved in the transition from relay-logic to the sophisticated controls & technologies and has seen the industry go from its ISO 9001 infancy to the new IATF 16949 standards that we have today. Bill also took an active part in the development of the Bose Wave radio and used one of the first ever Gas Assisted Injection units for body-side moldings for Ford. He is also familiar with the medical validation standards covered by FDA Title 21 CFR Part 820 Quality System Regulation. Bill has been fortunate to see many shops around the world and to start up four new production facilities. Along the way he taught himself AutoCAD and SolidWorks and devoted over half his life trying to understand the relationships between the mold, the material, and the machine.
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SKILLS
• Process Engineering • Plastics Injection Molding • Lean Manufacturing • RJG Master Molder Certified • Industrial Manufacturing • Six Sigma • SolidWorks |
• AutoCAD • 5S • Process Improvement • Research & Development • APQP • CAD • Product Development |
• PPAP • Project Engineering/Management • Mechanical Engineering • Maintenance • Forklift • Systems design • Industrial engineering |
Certifications & Licenses
• RJG Master Molder
• Engel Certified, Level 11
• Certified Kaizen Team Leader – 1998
• Currently enrolled at Community College pursuing Associate of Science Degree in Plastics Engineering Technology.
PROFESSIONAL EXPERIENCE
C&J Tech, Alexander City, AL
Lead Process Technician, 5/2023 - 6/2024
I am responsible for all technical functions of 25 LS injection molding machines. I oversee the mold setters and I start up the molds that they set. It falls to me to find, correct, and remediate anything that I find wrong in the setup or process. I am the technical authority on the night shift and also responsible for answering calls on my assigned machines which range from the mundane (running out of material) to the more challenging (mold problems and/or quality issues.)
Revere Plastics Systems, Auburn, AL
Technical Manager, 3/2021 - 3/2023
I was responsible for all of the technical requirements for a large custom molding facility. My duties include process, product, mechanical, industrial and facilities engineering. I was also the primary technical contact between our customers and the plant. The maintenance, tooling and process functions reported directly to me. I ensured that all new customers were given the same treatment regardless of whether they were automotive. They received the same documentation package. This guaranteed seamless integration into our QMS. During my tenure we grew from 3 functional IMMs to 17 with 2 additional presses onsite being refurbished. The month of February was our highest sales month ever and my technical group grew from 2 to 14 employees. Our machines ranged from 230T to 2450T and we processed a wide variety of materials ranging from commodity grade TPO to Xenoy (a PC/PBT blend).
Interplex-SunMED, Fort Lauderdale, FL
Senior Process Engineer, 1/2018 - 2/2021.
I was asked to come to Interplex to validate current medical jobs and to move all medical molding into a new facility. I was responsible for all technical aspects of the Injection Molding Department. The medical validation process encompasses far more detail than traditional APQP. Here I dealt with the entire process, from the initial Design Requirements to developing a validated process through Scientific Injection Molding to proving the efficacy of same through Operational and Performance Qualification runs. It also fell to me to oversee new project quotes, DFM and mold builds.
Thompson Plastics, Inc., Thompson, GA
Senior Manufacturing Engineer, 2/2016 - 10/2017
My primary focus here was on new and existing tooling. I was responsible for new tool quoting, design and build supervision. Thomson was new to ISO 9001, so I shepherded the plant through the certification process required for new automotive customers. My responsibility for the tools led management to ask that I take over the Mold Setup function as well. In this capacity, I oversaw the training and activities of all personnel involved in preparing a mold/machine for production. I also supported the plant engineering activities as led by the corporate Director of Engineering.
Valeo-FEM, Smyrna, TN
Senior Plastics Process Engineer, 2/2015 - 11/2015
I was responsible for all of the technical requirements for highly automated Injection Molding Machines which included new product launches and existing production jobs including DFEMAs, Control Plans, PFEMAs and work instructions. I also served as the Tooling Engineer for three projects that were launched. One of my major achievements at Valeo was the development of the mold and process that produced the first ever Automated Grill Shutter for an automobile. Senior management decided to split Maintenance from Process and Tooling which was done partly so that I could focus on the latter.
Magneti Marelli, Pulaski, TN
Process Engineer, 3/2014 - 2/2015
I was responsible for developing new molds into production-ready processes. I took new molds from delivery to the plant through troubleshooting to development of the process utilizing Scientific Molding techniques learned from RJG. This methodical approach provides a robust, machine-independent set of parameters that can be relied upon to produce consistent parts. My key deliverables were customer approved parts and the complete documentation package that supported the PPAP. I also served as a resource for the technical staff, as both mentor and coach.
Arkal Automotive, Auburn, AL
Process Technician, 8/2011 - 3/2014
I was responsible for all Processing, Tooling, Maintenance and Plant Engineering activities (even the landscaping.) This was a greenfield startup and I was there from dirt to full production. I oversaw the site preparation, building erection, machinery installation and startup. As part of my duties I also oversaw the construction and tryout of all new tooling for the plant. This required frequent overseas travel. I championed the team that created Arkal's Quality Manual and we obtained ISO 9001 certification on the first pass. PPAPs were my responsibility until we grew large enough to justify a dedicated quality staff. I watched the plant rise from nothing to being a major Tier 1 and Tier 2 automotive supplier.
ThermoFisher Scientific, Auburn, AL
Process Technician, 10/2008 - 8/2011
I was responsible for the creation of robust, scientific processes in the high-volume manufacture of disposable medical containers. I was also the primary source of training for all technical personnel. Our plant was destroyed by fire, and it fell to me to transfer all tooling to custom molders to ensure that our customers were not impacted. I spent six months traveling the southeast as the technical authority for the company.
Education and Certifications:
MSC Quality Technical Certification
Master Molder I, RJG Inc. 10/2008
Certified Kaizen Team Leader
Assorted Seminars from GE, Bayer, Engel, et. al.
Proficient in AutoCAD & SolidWorks
• RJG Master Molder
• Engel Certified, Level 11
• Certified Kaizen Team Leader – 1998
• Currently enrolled at Community College pursuing Associate of Science Degree in Plastics Engineering Technology.
PROFESSIONAL EXPERIENCE
C&J Tech, Alexander City, AL
Lead Process Technician, 5/2023 - 6/2024
I am responsible for all technical functions of 25 LS injection molding machines. I oversee the mold setters and I start up the molds that they set. It falls to me to find, correct, and remediate anything that I find wrong in the setup or process. I am the technical authority on the night shift and also responsible for answering calls on my assigned machines which range from the mundane (running out of material) to the more challenging (mold problems and/or quality issues.)
Revere Plastics Systems, Auburn, AL
Technical Manager, 3/2021 - 3/2023
I was responsible for all of the technical requirements for a large custom molding facility. My duties include process, product, mechanical, industrial and facilities engineering. I was also the primary technical contact between our customers and the plant. The maintenance, tooling and process functions reported directly to me. I ensured that all new customers were given the same treatment regardless of whether they were automotive. They received the same documentation package. This guaranteed seamless integration into our QMS. During my tenure we grew from 3 functional IMMs to 17 with 2 additional presses onsite being refurbished. The month of February was our highest sales month ever and my technical group grew from 2 to 14 employees. Our machines ranged from 230T to 2450T and we processed a wide variety of materials ranging from commodity grade TPO to Xenoy (a PC/PBT blend).
Interplex-SunMED, Fort Lauderdale, FL
Senior Process Engineer, 1/2018 - 2/2021.
I was asked to come to Interplex to validate current medical jobs and to move all medical molding into a new facility. I was responsible for all technical aspects of the Injection Molding Department. The medical validation process encompasses far more detail than traditional APQP. Here I dealt with the entire process, from the initial Design Requirements to developing a validated process through Scientific Injection Molding to proving the efficacy of same through Operational and Performance Qualification runs. It also fell to me to oversee new project quotes, DFM and mold builds.
Thompson Plastics, Inc., Thompson, GA
Senior Manufacturing Engineer, 2/2016 - 10/2017
My primary focus here was on new and existing tooling. I was responsible for new tool quoting, design and build supervision. Thomson was new to ISO 9001, so I shepherded the plant through the certification process required for new automotive customers. My responsibility for the tools led management to ask that I take over the Mold Setup function as well. In this capacity, I oversaw the training and activities of all personnel involved in preparing a mold/machine for production. I also supported the plant engineering activities as led by the corporate Director of Engineering.
Valeo-FEM, Smyrna, TN
Senior Plastics Process Engineer, 2/2015 - 11/2015
I was responsible for all of the technical requirements for highly automated Injection Molding Machines which included new product launches and existing production jobs including DFEMAs, Control Plans, PFEMAs and work instructions. I also served as the Tooling Engineer for three projects that were launched. One of my major achievements at Valeo was the development of the mold and process that produced the first ever Automated Grill Shutter for an automobile. Senior management decided to split Maintenance from Process and Tooling which was done partly so that I could focus on the latter.
Magneti Marelli, Pulaski, TN
Process Engineer, 3/2014 - 2/2015
I was responsible for developing new molds into production-ready processes. I took new molds from delivery to the plant through troubleshooting to development of the process utilizing Scientific Molding techniques learned from RJG. This methodical approach provides a robust, machine-independent set of parameters that can be relied upon to produce consistent parts. My key deliverables were customer approved parts and the complete documentation package that supported the PPAP. I also served as a resource for the technical staff, as both mentor and coach.
Arkal Automotive, Auburn, AL
Process Technician, 8/2011 - 3/2014
I was responsible for all Processing, Tooling, Maintenance and Plant Engineering activities (even the landscaping.) This was a greenfield startup and I was there from dirt to full production. I oversaw the site preparation, building erection, machinery installation and startup. As part of my duties I also oversaw the construction and tryout of all new tooling for the plant. This required frequent overseas travel. I championed the team that created Arkal's Quality Manual and we obtained ISO 9001 certification on the first pass. PPAPs were my responsibility until we grew large enough to justify a dedicated quality staff. I watched the plant rise from nothing to being a major Tier 1 and Tier 2 automotive supplier.
ThermoFisher Scientific, Auburn, AL
Process Technician, 10/2008 - 8/2011
I was responsible for the creation of robust, scientific processes in the high-volume manufacture of disposable medical containers. I was also the primary source of training for all technical personnel. Our plant was destroyed by fire, and it fell to me to transfer all tooling to custom molders to ensure that our customers were not impacted. I spent six months traveling the southeast as the technical authority for the company.
Education and Certifications:
MSC Quality Technical Certification
Master Molder I, RJG Inc. 10/2008
Certified Kaizen Team Leader
Assorted Seminars from GE, Bayer, Engel, et. al.
Proficient in AutoCAD & SolidWorks
