Randall Stepanek

*** ***** ***** *****

Hendersonville, TN 37075

260-***-****

acb7cm@r.postjobfree.com

INDUSTRIAL ENGINEER Software: Excel, Autocad,

Powerpoint, Word

Industrial Engineer Focused on Increasing Productivity, Time Study

Analysis, Plant Layout and Lean Manufacturing Concepts. Plant Floor and

Data Collection Emphasis. Detail-Oriented, Organized Performer with

Problem Solving Skills. Key Experience:

* Time Study Standards, Indirect Labor Standards, Work Sampling Analysis,

Pre-Determined Standards (Work Factor), Standard Data Development

* Plant Layout (Lean Cells, One Piece Flow), Takt Time / Bottleneck

Analysis,

Line Balancing, Practical Ergonomics, New Product Launch

* Capacity Studies, Plant Manning, Productivity-Efficiency Analysis

* Value Stream Process Mapping, Production Tracking, Routings, BOM

* Material Flow Analysis, Warehouse Layout, Containerization,

Packaging

* Quality: Operator Instructions, PFMEA, PFD, Statistics, Problem

Solving

* Standard Costing, Quotation, Variance Analysis, AOP Budgeting

WORK EXPERIENCE

Randall Stepanek, Industrial Engineer. 1981 to Date. Project/Contract

Industrial Engineering Involving Lean Manufacturing, Time Study Analysis,

Productivity Increase, Plant Layout, Capacity Analysis, Material Flow

Analysis and New Product Launch. Recent Projects:

Bridgestone. LaVergne, Tennessee. 9/2013 to Date. Inventory Analysis of

Extrusion and

Fabrication Processes to Determine Container Quantities and Storage

Space Requirements.

Plant Layout using Autocad. Production Efficiency Tracking.

NG Instruments. Warsaw, Indiana. 4/2013 to 9/2013. Time Study/Work

Sampling Analysis

to Develop Production/Set-Up Standards. Man-Machine Charting.

Capacity Analysis.

Boeing. Charleston, South Carolina. 11/2012 to 4/2013. Tablet Time Study

of Dreamliner

Composite Fabrication and Mandrel Assembly Operations Identifying Non-

Standard Work

and Delays. Value Added / Non-Value Added Analysis. Clean Room

Environment.

Revere Industries. Clyde, Ohio. 8 to 11/2012. Increase Productivity

Focus with Time Study,

Indirect Labor Work Sampling, Line Balancing Analysis and Man-Machine

Charting.

Lean Cells Plant Layout. Key Production Metrics Charting.

Bijur Delimon. Kinston, North Carolina. 12/2011 to 8/2012. Plant Layout

using Autocad of

Machining, Assembly and Warehousing Departments to Improve Material

Flow, Create Space

for New Business and Increase Productivity. Obtain Quotations.

Conduct Safety Audits.

PHD. Fort Wayne, Indiana. 9 to 12/2011. Time Study/Work Sampling

Analysis to Update

Standard Cost and Increase Plant Efficiency. Production Efficiency

Tracking.

Randall Stepanek

Page 2

WORK EXPERIENCE (continued)

Boeing. Everett, Washington. 7 to 9/2011. Supplier Assessment Scoring of

Key Manufacturing

Parameters with Primary Focus on Equipment Capacity and Manpower

Forecasting. Charts Development / Analysis to Meet Increased Production

Demand.

HON Corporation. Florence, Alabama. 7/2009 to 2/2011. Time Study

Standards Development

to Update Standard Cost and Increase Productivity. Processes include CNC

Saws, Lamination, CNC Routers, Assembly, Final Pack. Production Efficiency

Tracking. Routings Maintenance.

Zimmer. Warsaw, Indiana. 3/2005 to 4/2009. Time Study Standards

Development and Work

Sampling Analysis to Determine Capacity/Manpower Requirements and

Increase Productivity

Across Increasing Volume Product Lines (Hips, Knees, etc.). Lean

Manufacturing Layouts to

Improve Material Flow in Small Lot Size, One "Work Order" Flow

Environment with Clean

Room Operations. Standard Practices Establishment. Production

Efficiency Tracking.

Additional Clients include: Celestica, Tyco Industries, Franklin Electric,

Sunstrand, Walbro,

Johnson Controls, Freudenberg-N O K, Auburn Foundry, Ford Motor

Company, Alcoa,

General Motors, Hendrickson International, Northstar Aerospace, Guide

Corporation.

Accomplishments:

Conducted Value Stream Analysis, Process Mapping and Time Study with

Production Tracking in order to Increase Productivity: Buff/Polish (31%),

Plasma Spray (23%), Instrument Pack (19%), Fiber Metal (15%).

Converted Pack Line From Stand-Alone, Operator-Paced Method to JIT-Linked,

Conveyor-Paced Method Realizing a 30% Throughput Increase While Decreasing

Manning by a Third.

Plant Downsizing Plan (160,000 sq ft): Replacement of Foam Line and Final

Assembly Through Warehousing Revamp. Result: Plant Manning Reduced (from

350) by 37% Versus Plant Capacity Reduced by 15% - Yielding a 25% Labor

Dollar/Unit Reduction.

Plant Layout Consolidation (180,000 sq ft) to Accommodate Doubling of Sales

Volume. Equipment Addition Without New Building Construction.

Ergonomic Part Handling Enhancements on Multi-Press Stamping Lines

Achieving a 20% Productivity Increase.

Completed Several Time Study Standards Development Projects Identifying

Productivity Increase Opportunities and Capacity Contraints.

EDUCATION, TRAINING

Purdue University, West Lafayette, Indiana

Bachelor of Science Degree, 1980

GPA: 5.22 (A=6)

Major: Supervision

Minor: Industrial Engineering Technology, Business Management

Training/Seminars: Shainin Technical Problem Solving, Lean Manufacturing,

ISO Audit,

Management Decision Making (Kepner-

Tregoe), Industrial Ergonomics,

Indirect Labor Work Sampling, Work Factor Pre-Determined

Standards,

Gainsharing, Security Measures, Continuous Improvement:

Seven Wastes,

Value Stream Mapping, 5-S, Gemba.

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