Plastic lined metallic pipe expert
Plastic Lined Metallic Pipe Expert
David Yanik
PictureDavid Yanik is a plastic lined metallic pipe expert residing in North Carolina.
Creative engineering professional and team builder, with experience in product development and design validation, sustaining engineering, productivity improvement and design control as well as direct operational experience in industrial engineering, lean manufacturing and production management.  Customer training presentations and mentoring young engineers are particular strengths.
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Experience
Engineering Consultant
August 2022 - Present
Self employed, Asheville, NC        
  • Free lance engineering consultant assisting with new product development, product launch, failure analysis, equipment specification and Codes and Standards committee work.

Product Engineering Manager                                                       
April 2006 – July 2022
Crane Resistoflex, Marion, NC
  • Responsible to Vice President and General Manager for all product development and sustaining engineering activities.  Oversaw staff of up to nine engineers, as well as test lab supervisor, and drafting / database supervisor.
  • Led product development teams through stage/gate NPD process to develop a variety of products for the chemical process and energy sectors.  These included, but were not limited to
    • Complete large diameter (14”-48” NPS) Polypropylene lined pipe and fitting product platform targeted at high volume seawater applications.  This project entailed $4.0M capital investment and has Mature Annual Sales projections of greater than $20M.  Commercial launch occurred in March 2019.
    • 1”-12” Permeation resistant PTFE lined pipe and fitting system for severe service chemical process applications.  Commercial launch occurred in June 2011 (Marketed under the trade name "ATL ™" for Advanced Technology Liner)
    • High dielectric strength PTFE (Teflon®) hoses for 300-1100 MW generator cooling applications.  These are custom formed and fitted for specific generator configurations.
  • Responsible for field failure analysis, and creation of technical reports to customers on root cause and countermeasures.
  • Active member of ASME B31.3 Process Piping Code committee subgroup F on nonmetallic piping systems.
  • Chair of ASME NM.1 subcommittee on Materials. 
  • Author of three white papers on the following subjects:
    • Plastic lined piping system advancements
    • Bioprocess risks for high purity hose applications, (this was later published in Hose and Coupling magazine, a trade publication)
    • New developments in large diameter plastic lined piping
  • Co-author of the book “Design, Installation, Maintenance and Inspection of Metallic Plastic Lined Piping” under contract to the Materials Technology Institute.  The intent of the book is to improve safety and performance for the small but critically important community of plastic lined piping users.  The book was published summer 2016, (Second edition in process)
  • Led project activity related to the closure and relocation of a small (60 headcount) manufacturing operation from Pforzheim Germany to three sites in Marion, NC, Waalwijk, The Netherlands, and Congleton, UK.
  • Led project to source, install and startup equipment in Suzhou, China service center providing full pipe fabricating and lining capability for local market sales.

Lean Production Manager
August, 2004 - 2006
Crane Resistoflex, Marion, NC    
  •  Responsible to Operations manager for all manufacturing, shipping, receiving, tool room and maintenance functions.  Managed staff of ten supervisory personnel, who in turn oversaw seventy to one hundred direct labor and support personnel.
  • Responsible for shipping budget projections, safety, scrap remediation, factory performance review system, disciplinary actions, hiring, firing and all interface with engineering, accounting, procurement, planning and human resources.
  • Responsible for process and cost improvements through kaizen.  Led or served on an average of two kaizen teams per month.

Industrial Engineering and Design Manager
August, 1998 –2004
Crane Resistoflex, Marion, NC    
  • Direct management of a staff of industrial engineers, database coordinators and CAD technicians in a fast paced environment fabricating and assembling mechanical piping, hose, vessels and complex welded pipe constructs.
  • Managed closure and relocation of manufacturing plant from Bay City, MI to Marion, NC.  Responsibility included justification of $1.5 million capital expenditure, planning and oversight of addition of approximately 40,000 square feet of new construction in Marion, and logistics of setting up of product lines in new location.. 
  • Oversaw multi-disciplined team responsible for integration of newly acquired plant in Pforzheim, Germany into the Pro-Alpha ERP system.
  • Provided an advisory function and drafting service to the R & D and product maintenance engineering staff

Product Engineer
1995 - 1998
Bussmann Division of Cooper Industries, Black Mountain, NC
  • Primary design responsibility for redesign, design validation and implementation to production of flagship line of UL® listed current limiting 250 VAC and 600 VAC fuses.  Project involved $1.8 million capital spending and $1.3 million annual savings.
  • Managed aggressive list of smaller redesign and product maintenance projects.
  • Worked directly with end-users to develop new designs for special application transportation fuses.  An example is the development of a 750 VDC "shoe" fuse for train cars used in various municipal transit systems. 

Industrial Engineer                                                                                                             
1987 -1995
Bussmann Division of Cooper Industries, Black Mountain, NC                                                                                                                                                                       
  • Oversaw remote, (manufacturing site) implementation of WMS, with complete integration with St Louis distribution center, installed hardware and trained all packaging personnel  in operation of the software and hardware.
  • Designed custom fabrication and assembly machines for the purpose of automation. 

EDUCATION & CERTIFICATIONS
  • 3P Tool Champion 2012
  • Lean Green Belt, Crane University 2002                                   
  • Master of Engineering (ME), North Carolina State University 1996                                                
  • Bachelor of Science Mfg. Eng. Tech. (BSMET) Western Carolina University 1987                         
  • Associate of Applied Science Mechanical Engineering Tech, (AAS) ABTCC          1981
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