Engineer Project

Josef Bozek

630-***-**** Cell 630-***-**** • *******@*****.***

PROJECT MECHANICAL ENGINEER

Self-motivated, dedicated and reliable professional with proven engineering / manufacturing experience.

• Machinery and tooling projects / design of tooling and fixtures for sheet metal products, 2D & 3D CAD / project management / new product development and upgrading/ troubleshooting, process improvement/

• Reliability improvement, preventative maintenance and support to company products and services.

Project design / execution of multiple projects Project completion according to plans

Resource for materials and labor forecasting Review accuracy of costs and budget

Cost savings / ongoing process improvement Failure analysis and problem solving

Engineering quality control / ISO 9000 series New product development process

Technical Proficiency: AutoCAD, SolidWorks and Unigraphics NX, Six Sigma DMAIC, SPC, FMEA.

PROFESSIONAL EXPERIENCE

Project Engineer, 2007 - Present

Provided engineering design, support and expertise to several companies/industry leaders offering new products, services and solutions to valued customers. Contracts experience and work achievements include a following:

• Standardized parts of prototype of Flexco hydraulic and mechanical applicators used for joining mining coveyor belts at Flexco Co., Downers Grove,IL. Converted CAD 3D part models and documentation to ISO metric system.

• Implemented cost saving solutions and methods in automotive parts assembly operations at Cosmos Manufacturing Co. Designed welding fixture for partial and final product assembly, fixtures for CNC machining and laser cutting, designed and improved stamping progressive dies.

• Managed design, built prototype and tested automated deburring cells for impact extruded aluminum products at JLO Metal Products in Chicago IL. Provided solution and design for unconventional tooling (stamping, drawing, forming, trimming) used in postextrusion operations minimizing part’s machining time and reducing overall piece price cost.

• Optimized process production of flux cored wire welding electrodes at ESAB Welding And Cutting Products Company at Hanover PA through modernization of roll forming operations and implementation of standardization of new design of tooling and processes. These improvements contributed to reduction of down time of production lines 3% and scrap reduction 1.5%.

• Designed entirely a new generation of mobile electric resistance welder for repair of railroad rails at Holland Co., Crete, IL. This 12,000 lbs globally unique hydraulic operated mobile high current resistance welder is to speed up the process of repair of fractured railroad rail up to 50% as well as improve weld durability and safety.

• Designed, developed and tested new tubular product line for Tycho Company; reduced lead time by 20% as well as overall cost through robust design of tooling, and application of controls and special fixtures.

• Entrusted as engineering solution resource using CAD to design key components of steel mill equipment for Arcelor-Mittal, U.S. Steel and Beta Steel plant at Capital Engineering, Hammond, Indiana; improved quality of steel plates and increased mill productivity by solving slab’s cooling process.

• Designed and built prototype of cyclone system at Wrigley Manufacturing Company, Yorkville, IL, resulted in waste reduction of up to 25% of sweetener powder and placing 60,000 lbs. of sweetener back into production; resulted in a cost savings of $1.2 million.

Tooling Engineer, Lone Star Steel, Lone Star, Texas, 2005 - 2007

• Developed plan to increase productivity of high-frequency welding tube mill by 5% or 24,000T of tubing.

• Improved mills / tooling / equipment reliability using Root Cause Analysis / DMAIC process improvement.

• Solution resource recognized for minimizing mill line bottleneck problems; improved pipe transfer between multi-directional conveyors and installed pipe guiding system, redesigned and rebuilt flying plasma cut-off to eliminate tube’s cut mismatch.

• Used CAD SolidWorks to design tube mill components, tube conveyors, progressive roll tooling, fixtures, run-out tables, high pressure water descaler, skelp slitting line, mill stands, shafts, weld boxes, drives and gears..

• Planned, managed and controlled of contractors work and project phases.

Project Engineer / UG CAD Designer, 2003 - 2005

• Project at Hendrickson International, Woodridge, Illinois –managed design and fabrication of 60-ton steel structure of Tandem Test Rig Cell for truck’s suspension and drive systems.

• This unique design, one of two in the world, replaces the traditional way of testing durability of automotive products and leads to cost savings through laboratory analytical testing.

• Used UG CAD to design and detail truck’s suspension and brake system components.

Senior Manufacturing Engineer, Silgan Closures LLC, formerly White Cap, Chicago, Illinois, 2000 - 2003

• Managed design / installation of a $2 million metal closures project for a new facility in Queretaro, Mexico. This company is a leading global supplier of metal, plastic and composite vacuum holding closures.

• Performed project scheduling, cost analysis, tracking of work progress / project phases, milestone setting, hiring, supervising and mentoring contractors, installing and evaluating new / used machines.

• Developed plans to improve productivity through application of lean philosophy / Kaizen 5S that resulted in eliminating waste, reducing downtime, failure analyses and poka yoke (fool-proofing) of change parts.

• Directed and coordinated process development / improvement of metal closures product line, FEA by means of Cosmos/Design Star, GD&T, BOM, CAD shop production drawings.

• Implemented Design for Manufacturing (DFM) methodology, which resulted in standardization, improving reliability and cost effectiveness of manufacturing.

• Improved automation / related processes through application of pneumatics, vacuum systems, rare earth magnetic materials, electronic controls (PLC’s), drives and gears.

• Designed high precision tooling including compound dies, rotary hem tooling; increased tooling life 3 times through investigation and application of superior strength alloy steels and carbides.

Project Engineer, 1998 - 2000

• Improved efficiency of quenching process of hot-rolled aluminum plate at McCook Metals (formerly Reynolds Aluminum), McCook, Illinois; designed mill replacement components, tooling and fixtures for special purpose rolled plates (diamond tread).

• Developed and refined manufacturing processes to reduce costs and improve productivity of roll formed sheet metal parts for automotive, metal furniture and home appliance industries.

• Designed stamping and roll forming tooling; provided technical support, equipment specifications and layout; monitored conformity to quality standards.

Design Engineer, 1993 - 1998

Completed several key projects, including design, development and execution at tube mill manufacturing companies including T&H Machine Company, Addison, Illinois, and Chicago Roll Company, Lombard, Illinois.

• Designed and developed new roll forming and steel tubing machinery.

• On-site installation of new roll formers and tooling; revised customer’s existing process to reduce manufacturing costs, improve quality and eliminate waste.

• Supervised fabrication, design and development of machine components, e.g., body weldments / casting parts, worm gears, drives, shafts, stands and fixtures.

• Managed design of new metal profiles and progressive roll tooling using CAD / bending stress analysis.

• Supported CNC turning, milling and OD / ID grinding departments; resolved CAD / CAM tool path programming concerns; provided recommendations for tooling heat treating and related processes.

• Conducted tooling / new product trials on pilot line; trained machine operators; performed tooling quotes.

• Collaborated with sales, suppliers, purchasing and inventory management personnel.

EDUCATION

Master of Science in Mechanical Engineering, University of Technology, Gdansk, Poland

Certifications:

• Six Sigma Green Belt

• Unigraphics official training

• SolidWorks License

• Flodyne-Hydrodyne School of Hydraulics and Pneumatics

Software: Microsoft Project, Excel, Word, and Quality Companion.

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