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then i called our sysadmin ( i am not sys admin ) who told me to rename ksh.
Does he ( your sysadmin) remember most users on HPUX have /usr/bin/ksh as default shell (in /etc/passwd...)?
What if root can login only at the console, and no one were connected? Who will su root?...
When you say 400 proc max, what value are you talking about? nproc or maxuprc?
The difference? One is global - for all the system, the other is per user...
I, would start by removing . in the path of that user, if not enough, change his login shell to rksh and perhaps use script to see what he is up to, this reminds me - Have you looked in his .sh_history to see what he was doing ? This may give you some clues...
And you have mentioned you had scripts that may be the cause , I would go and chase them and I would remove execute permission on them, then try to understand their content...