John Allen specializes in the application of engineering principles within the context of product performance, product durability, and reliability improvement in manufacturing companies. John's clients have included General Motors, Pratt & Whitney, General Electric, Rolls Royce, US Steel, Delphi, Philips Consumer Electronics, Siemens Electronics and others. He has worked in foundries and chemical companies, and on precision machining, plastic molding, precision assembly and extrusion and blown film. John has worked on planes, trains, and automobiles around the world.
John's reputation is based upon his ability to efficiently assist clients in solving complex technical problems. There are three projects that solidified his reputation. The first involved defects in cast aluminum heads. Scrap was in excess of 50%, much of it not found until after machining or installation in the vehicle, causing assembly line stops and warranty problems. John's small team reduced the scrap to less than 1%, eliminated warranty claims for the defect, and virtually eliminated machining scrap. The project required only several days of John's time over the course of a few weeks.
Another important project was at a smelter, which suffered from broken furnace electrodes for more than 50 years. The life of the electrodes was unpredictable, requiring frequent furnace outages. Over the course of one year (it took 6 - 8 months to manufacture and consume an electrode) the life of the best electrodes was extended by 40%, broken electrodes were eliminated, and this type of furnace became one of the most productive in the world. The additional cost to produce these efficient electrodes was about $3 for an electrode that cost in excess of $5,000.
One more impressive project was for air seals in aircraft engines. Another team, over the course of two years, reduced scrap from 40% to 20% and stated that no further progress could be expected. John and his small team took over. At the end of the project, scrap was less than 1% for these delicate components.
John has a reputation for completing complex product performance and reliability projects quickly.
John Allen is a respected speaker and lecturer. For years, he taught Shainin Statistical Engineering seminars, was an annual presenter at the Shainin Symposium, and was a keynote speaker at the Daimler Chrysler 2003 Black Belt Symposium. John spoke at a conference of West Coast Universities, delivering a speech, "Emulation and Invention: Strategy, Structure and Tactics." He was recognized in January 2002 by Shainin LLC as the first Shainin Fellow for his contributions as Director of Technology, for his ability to teach clients, for solving technical problems and for training consultants.
John is an avid sailor, and reader of the history of science. John lives in Rye, New Hampshire.