1. Brian D. Thomas, Sr.
222 Blackwater Dr • Harvest, AL 35749
256-665-6377 •• bdthomassr@yahoo.com
RUBBER SCIENCE AND TECHNOLOGY EXPERT CONSULTANT
Innovator • Leading Edge • Data Driven
A creative problem solver and innovator for over 30 years, materials specialist, rubber
compounder, team leader, R&D manager, corporate rubber operations director and company
founder specializing in rubber materials engineering, science and technology focused mainly on
tires and windshield wipers. Expertise in product development includes competitive
benchmarking; rubber and coatings compounding, mixing and processing; laboratory and
functional testing; quality control; continuous improvement. A multi-disciplinary team leader
and budget-conscious project manager with a broad range of technical and management skills.
Core Competencies and Skills
• Rubber Compound Design • Molding/Extrusion • Curing
• Post Treatments • DOE • Productivity Improvement
• Waste/Scrap Reduction • Cost Reduction • Test Development
• Physical/Analytical Testing • Product Performance Improvement • Forensic Analysis
• Reverse Engineering • FMEA/DFMEA • SPC
Consulting
• Forensic analysis of passenger and light truck tires.
• Directed the development of windshield wiper rubber parts with improved set and low
temperature performance. Developed natural rubber and natural/synthetic blend compounds
along with a low friction coating with improved durability.
• Generated budgets, reports, schedules, product specifications and customer/management
presentations.
Tire Compound Development/Manufacture
• Designed all-weather, low rolling resistance, excellent traction /handling rubber compounds
(tread, undertread, sidewall, belt, apex, bead, carcass, liner) for Original Equipment passenger
and truck tire applications; assumed full responsibility for all aspects from development and
manufacture to performance and reliability.
• Continuous improvement – Analyzed failed tires, both returned and on site in the field (i.e.
tread separations, wire adhesion failure, belt ply delamination, sidewall degradation/ozone
cracking, irregular and premature tread wear, etc.). Determined cause of failure using state-
of-the-art analytical instruments and methods including TGA, FTIR, GC, DMA, DSC, HPLC,
SEM/EDX, then specified corrective action(s) through compound redesign or process
modification.
• Minimized waste, redundancy, product costs; and enhanced product yield. Experience with
decreased plant scrap, calendaring, mixing, extrusion, and curing.
Page 1 of 3

2. Brian D. Thomas, Sr.
222 Blackwater Dr • Harvest, AL 35749
256-665-6377 •• bdthomassr@yahoo.com
• Specified and approved preferred suppliers as a materials specialist.
Windshield Wiper Compound Development/Manufacture
• Designed low permanent set, high durability, all-weather natural and synthetic rubber
compounds, processes and low-friction coatings for Original Equipment and After Market
applications – for molding and extrusion.
• Developed and set mixing, extrusion and curing parameters.
• Established friction-reducing surface treatment parameters.
• Tested product and developed specifications to ASTM, ISO and customer standards,
DFMEA’s, FMEA’s.
• Process Control – Used SPC to improve production process control of critical characteristics
and solved production related problems in the factory using statistical engineering methods.
Waste reduction, yield optimization.
Experience
Sole Proprietor
THOMAS CONSULTING • Harvest, AL
Rubber science and technology consulting specializing in tire and windshield wiper compound
and process development; project management and personal development.
• Develop rubber compounds and processes for tire and windshield wiper applications.
• Perform material and production data reviews, physical inspections and laboratory analyses
to determine cause(s) of tire failures for several law firms.
• Generate reports, recommendations, billing, accounting
• Expert witness – most cases settle favorably out of court.
Director, Rubber Business Group
KYUNG CHANG WIPER COMPANY (KCW) • Daegu, South Korea
International manufacturer of windshield wipers and miscellaneous automotive products.
• Directed all rubber related areas, processes and personnel from R&D to production.
• Designed natural and synthetic rubber compounds for Original Equipment and After Market
applications, for molding and extrusion processes. Assumed full responsibility for all aspects
of the compounds from manufacture to performance and reliability. Developed
specifications, DFMEA’s, FMEA’s. Improved high and low temperature set by 50% with
increased durability resulting in improved wipe quality durability and reduced noise.
• Analyzed failed wipers – returned and on site in the field (i.e. pre-mature wipe or noise
failure, etc.). Determined cause of failure using state-of-the-art analytical instruments and
methods including TGA, FTIR, GC, DMA, DSC, HPLC, SEM/EDX, then specified
corrective action(s) through compound redesign or process modification.
• Reverse-engineered and bench-marked competitive products from other major companies.
Page 2 of 3

3. Brian D. Thomas, Sr.
222 Blackwater Dr • Harvest, AL 35749
256-665-6377 •• bdthomassr@yahoo.com
• Performed extensive research in material properties and effects on performance parameters.
• Improved production process control and solved production related problems in the factory
using statistical engineering methods.
• Developed highly trained employees; specified departmental goals and objectives; set
priorities; created highly specific project management programs, budgets, capital requests,
operating systems, policies and procedures, training programs; performed evaluations.
Activated methodologies for workflow and delegation in a multi-disciplinary environment.
Other Experience
Territory Manager
ACUSHNET RUBBER COMPANY
Manager, Elastomers Research and Development
TRICO PRODUCTS CORPORATION
Original Equipment Compounder
DUNLOP TIRE COMPANY
Compounder
GOODYEAR TIRE & RUBBER COMPANY
Affiliations
American Chemical Society and American Chemical Society Rubber Division, SAE
Education
Bachelor of Science in Chemistry, Alabama A&M University • Normal, Alabama
Continuing Education
Rubber Compounding and Materials, Viscoelastic Properties of Elastomers, Plastics, Analytical
Techniques, ISO9000, QS9000
Certifications
Statistical Process Control, Statistical Engineering, Design of Experiments
Page 3 of 3