QUALIFICATIONS

Consultant - 11 years

• Conducted five week in depth evaluation of processes and equipment of the multi-foundry operations of a major eastern European steel producer, resulting in detailed short and long term recommendations for modifications aimed at restoring profitability to the organization.
• Compiled documentation and co-ordinated activities of both ISO 9000 (Quality Management Systems) and ISO 14000 (Environmental Management Systems) for a major ferro-alloy producer.  Successfully directed transition to the new ISO 9001:2000 standard, obtaining unconditional approval in the first attempt at third party audit and registration.
• Developed and documented standardized gating and risering practices handbook for gray and ductile iron foundry
• Trouble shoot ductile iron processing, fading and dross problems for jobbing foundry operation
• Redesigned molding and pouring operations to optimize productivity in small gray and ductile iron facility
• For jobbing operation, developed process control procedures for melting and casting heavy section ductile iron.

Manager, Process Control  - 9 years

• Responsible for all Quality Assurance/Process Control activities in a gray and ductile iron foundry producing castings from 100 to 100,000 pounds.
• Responsibilities included the Melting Department, Sand and Metals Testing Laboratory, Pattern Shop, and casting engineering
• Developed annual operating budgets and capital expenditure plans
• Coordinated all foundry activities and procedure development for ISO 9000 qualification
• Qualified the Foundry Laboratory for testing of components for the nuclear applications.

• Responsible for non-captive inside casting sales and coordination of sales representative activity.
• Developed costing and pricing guidelines, formal quotation practices, and coordinated order entry.

• Responsible for 125 man gray and ductile iron foundry facility employing automatic core making and molding process.
• Increased productivity up to 60 percent through the better utilization of personnel as well as equipment modernization.
• Implemented innovative ductile iron treatment methods, which improved productivity, reduced scrap and processing costs.
• Developed PC based production and scrap analysis system which identified problem areas in a timely and accurate manner.
• Trained personnel in Statistical Process Control techniques for the control of various foundry processes, and administered the SPC program.

Technical Manager, Manager of Quality Assurance, Metallurgist - 8 years

• Responsible for metallurgical and technical phases of foundry operations including green sand and chemically bonded sand molding and core making, electric arc and induction furnace melting, raw material specifications and vendor approval, process control, inspection and quality assurance systems, pattern design and casting engineering, chemical and mechanical testing, heat treating and welding.

• Developed and implemented plant-wide Quality Control/Quality Assurance system and operating procedures, for the production of steel castings, upgrading a facility previously dedicated to gray iron production.

• Current corresponding member of AFS Gating and Risering Committee

• Served on various local chapter, and national technical and specification committees for the American Foundrymen's Society (AFS), the Steel Founders Society of America (SFSA), and the American Society for Testing and Materials (ASTM).

• Participated in three year program with the Steel Founders' Society of America, assisting the Technical and Research Directors in preparation and editing of technical/research reports, and the presentation of SFSA technical seminars and other activities.

 

 
 











PUBLICATIONS

Gall, E. M., and P. F. Wieser, "Strength - Toughness Relationships for Cast Steel", Journal of Steel Castings Research, No. 64, September, 1973.

Townsend, P., E. M. Gall, and P. F. Wieser, The Toughness of Cast Steels: NDTT, Charpy V-Notch, and Dynamic Tear Tests, Research Report No. 80, Steel Founders' Society of America, 1974.

Gall, E. M., "A Literature Review of the Characteristics and Evaluation of Foundry Grinding Systems", SFSA Technical Folio, December, 1974.

Contributing Author to the Steel Castings Handbook, Fifth Edition, Steel Founders' Society of America, 1980.

Bachelor of Science, Metallurgical Engineering (1972)                  Case Western Reserve University
                                                                                                            Cleveland, Ohio

Master of Business Administration (1983)                                    Wilkes College
                                                                                                             Wilkes-Barre, Pennsylvania

For more information, e-mail us at emgall@consultation-services.com.

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