Engineer Plant
Resume:
Randall Stepanek
Hendersonville, TN 37075
***************@*****.***
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.
Contact this candidate