Larry Schappell Kutztown, PA 19530 Phone: 610-683-3550 Email: larry@schappell.

com

LITHIUM BATTERY DEVELOPMENT MANAGER

Process development manager of lithium ion and polymer technologies with proven success in managing teams to develop innovative processes. Solid operations and purchasing management skills from directing prototype manufacturing for seven years. Strong skills in applying statistical analysis tools(Six Sigma, DOE, Taguchi, etc.) to troubleshoot and improve process systems.

PROFESSIONAL EXPERIENCE

Lithium Battery Development Consultant/Contractor; 2008-present. Part-time support to two lithium battery technology development firms. Completed set-up of lab-scale flat cell production system. Developed separator coating tools. Produced cells for evaluation of various separator parameters. Lithium Technology Corporation., Plymouth Meeting, PA 10 yrs.; 1998-2008. Start-up lithium battery manufacturer with less than 100 employees. Director of Flat Cell Manufacturing & Process Development responsible for lithium ion flat cell prototype production, testing, process development, purchasing, shipping and receiving. Developed large format flat cells for telecommunications and military applications. Evaluated alternative production techniques to improve productivity and cell quality. Identified causes of major performance issue with a screening design that identified key activation variables and optimum levels to eliminate the performance issue. Evaluated electrode materials for scale-up with pilot-plant coatings, cell builds and testing. Optimized coating techniques to improve coating uniformity and cell performance. Developed coating technology with toll coater and increased cell production more than 100%. Created production operating procedures(SOPs), logs and reports to produce consistent quality cells and provide tracking of components to enhance process troubleshooting. Defined raw material usage/inventory models to insure timely purchases and best order quantities. Air Products & Chemicals, Allentown, PA 17 years; 1979-1996. Major gases and chemicals manufacturer with more than 9,000 employees. Technical Manager of PVC resin plant responsible for process engineering group in the revamp and restart of a large reactor PVC resin plant. Achieved 30% higher production rate within six months. Developed and implemented debottlenecking program that further increased productivity 15% and contribution $2 million per year. Identified cause of poor resin thermal stability. Designed an antistat system that prevented customer handling problems.

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Lead Development Engineer responsible for supervising two engineers in the scale-up and optimization of suspension PVC resins and processes. Developed alternate reactor cleaning technology resulting in $100,000 savings per year and 4% productivity increase. Improved flexible grade PVC porosity and color 10% and gels 20%. Reduced PVC resin bulk density variability by 20%. Identified and reduced the effect of variable reactor cooling rates on PVC properties. Lead Development Engineer responsible for the scale-up and optimization of vinyl acetatebased emulsion and suspension adhesive polymers. Led multi-disciplinary team that identified primary causes of poor water resistance and shear stability of adhesive polymers and improved these properties 15%. Replaced suspension grades' initiator to eliminate residual byproduct. Scaled-up low volatiles technology for base adhesive products. Transferred suspension grade technology to non-polymer licensee. Product Manager responsible for coordinating PVC product issues with manufacturing, sales, marketing and R&D. Developed PC-based customer specifications system and inventory model to aid in production scheduling.

EDUCATION

M.B.A. Kutztown University of Pa B.S. Chemical Engineering, Pennsylvania State University

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