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Engineer Manufacturing

Vernon Hills, IL, 60061
October 31, 2018

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Thomas R. Hornbostel

*** *. ****** **. - ****** Hills, Ill. 60061 - Home 847-***-****

E-mail: - Cell 224-***-****

Manufacturing Engineering / Project Management / Principal Engineer

Twenty years experience in analytical skills, effectively manage complex projects. Seven

years experience in medical pharmaceutical industry reducing costs and submitting

regulatory packaging changes. Extensive experience both in manufacturing and process

engineering, proven skills in project management, cost/quality improvement, vendor

relations, project funding, justification process and capital expenditure.


2011-Current Principal Engineer and Operations Strategy and Finance Analyst

Pfizer / Hospira Lake Forest, Illinois. ( Contract position )

Creating packaging changes to meet requirements to enter foreign markets for Global expansion. Experience in engineering change, approval and packaging validation process through SAP. Experience with team dossier writing, submittal and approval process into foreign countries. Development implementation and validation of improvements to current packaging to reduce damage in overseas shipments. FMEA’s, testing and validation of packaging through process testing.

Analyzing molecules sold in Europe, developing and recommending action plans and projects to reduce cost of goods sold.

2010-2011 Manufacturing Engineer

Honeywell Analytics Inc., Lincolnshire, Illinois. ( Contract position )

Process Improvements through updating BOM’s, writing and implementing ECO’S and developing Standard Work documenting with digital pictures the best practice process.

Actively performing needed daily manufacturing engineering support for the Industrial Gas detector production area, through testing and problem solving.

Consistently taking on additional duties, Lean Leadership training, designing and building Cre-form flow racks, Rail review, Continuous Improvement and Kaizen weekly reviews.

2008-2010 Manufacturing Engineer

Zebra Technologies Corporation, Vernon Hills, Illinois. ( Contract position )

Actively supported 4 - 5 Manufacturing lines as well as a large kit department. Work Instruction development ( with digital pictures ), ECO’s and daily manufacturing problem support and solutions.

New Product Development test trials and participated on product launch teams.

Lead customer complaint weekly discussion meetings and facilitated product updates, changes and manufacturing process updates.

2006-2007 Manufacturing Engineer

Knaack Manufacturing Co. Crystal Lake, Illinois.

Kaizen Team Leader, resulting in over $ 55,500 in labor savings on welding lines.

Kaizen Team Leader, team developed and implemented turret, press brake and shear cell, combining operations, having an operator run cell resulting in savings of $29,000.

Improved Paint Line conveyor capacity by improving box/cabinet removal with Lift and Tilter system, by safely eliminating use of a fork truck and a savings of over $ 39,000.

2004-2006 Manufacturing / Project Engineer

Weber Stephen Products Co., Palatine, Illinois.

Developed and implemented Adige Laser equipment to cut stainless steel parts in house resulting in a project payback of 2.8 years. Trained and certified Laser Safety Officer for Class 4 laser and able to program parts for cutting in accutube specialized software.

Worked with union representatives in cost reduction labor saving projects in Haven cutting and robotic work cells in an effort to meet company EVA cost reduction goals.

Experience (Continued) Thomas R. Hornbostel page 2

2001-2003 Industrial / Project Engineer

Nu-Way Industries, Des Plaines, Illinois.

Developed extensive work instructions for assembly of electrical cabinets with complex wiring diagrams for the Motorola assembly area.

Updated, corrected and maintained Bills of Material, routings with production standards and shop floor orders for cost review and proper analysis of job profitability and production costs. Corrected and developed incoming material orders for better utilization.

Analyzed work force utilization and layout for JC Decaux bus shelter assembly cells.

1999-2000 Industrial / Quality Engineer

Allegheny Rodney Corporation ( formerly Alstrip, Inc. ) Skokie, Illinois.

Analyzed and developed production standards for company gain sharing program for the slitter processing lines.

Lead Safety Program and implemented new operational changes and additional safety requirements to reduce OSHA incident and recordable rates through plant and Safety committee meetings. The result of a reduction of over 25 %.

Developed tracking of incoming material and vendors to reduce in-house lead times through Vendor Delivery Performance reports. Developed and prioritized bi-monthly maintenance items.

1986-1999 Industrial / Project Engineer

Federal Mogul Corporation ( formerly Fel-Pro, Inc. ), Skokie, Illinois.

Professional Achievements

Involved on a daily basis in on-the floor problem solving, assisting Team Leaders in

implementing procedures for inspections to reduce potential errors.

Evaluated and purchased ergonomic equipment to reduce assembler’s fatigue.

Performed cost justification for capital equipment acquisitions totaling $ 250,000.

Developed daily production, downtime and efficiency reports using Excel, Microsoft Word and Project Management.

Analyzed, updated and maintained accurate testing programs for equipment.

Performed quality assurance inspections to comply with QS 9000 audit procedures.

Developed and implemented safety programs that resulted in a 20 % decrease in on the job injuries in the packaging division.

Enhanced PC skills through continuing education classes in Auto Cad 12, Project Management, Business writing, Value Analysis and Cost reduction processes.

Responsible to investigate and develop plans for implementation of purchased

capital equipment and determined operating procedures.

Recommended and purchased equipment for automating headbolt boxing operation. Resulted in an annual savings of $ 120,000. Received company recognition for best team cost reduction project in 1997.

Developed a new single pack in-line automated equipment to insert a card and a part into a printed film sleeve. Yearly labor savings was calculated at $ 150,000. Recognized as third best team cost reduction project in 1996.

Analyzed, reduced and automated high volume subassembly processes through the purchase of bowlfeeders and autobag equipment with printers.

Cost savings of $ 200,000 per year.

Installed Zed skin packaging line with cutting dies to reduce labor. Annual material and labor savings of $ 39,000.

Implemented large crane film hoists for loading large rolls of plastic film. Speed increase and safety project resulted in a labor savings of $ 12,500 annually.

Education MBA, major in Finance, Roosevelt University, Chicago, Illinois 1991.

B.S., Industrial Engineering, Bradley University, Peoria, Illinois,1985.

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