Thomas E. Hankes

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

312-***-****

e-mail:adhak4@r.postjobfree.com

Objective

To obtain a position in a world class organization striving for continuous improvement through Lean Principles and process improvements driven to improve customer satisfaction.

Core Competencies

●Extensive background in increasing production efficiencies through Continuous improvement (Standard Work,5's, Kaizen Activities, Value Streams, Elimination of NVA)

●Hands-on employee training during Kaizen Activities and introduction of new Standard Work Process to shop floor.

●Managed and trained workforce up to 100 operators

●Equipment acquisitions and maintenance scheduling

●Experience in plant layouts and process design

●Process standardization and documentation via routings and BOMs

●Management and personnel development through training

Work experience

Mifab

Plant Manager September 2014-present

Responsible for 62 employees' for a multi- technology facility (press brake, sheet metal laser, spot welding, mig/tig welding, and powder coat system with $30 million in annual sales producing custom and stock items. Duties include creating a safe workplace, manpower scheduling, creation, training and implementation of Standard work process,schedule attainment, on-time delivery, quality assurance, and schedule preventative maintenance. Duties also include new equipment justifications and acquisitions, job quoting for one off items, inventory control and accuracy and ordering of replacement tooling.

Accomplishments:

●Reduced WIP by 25% through Kaizen improvements and Standard Work

●Developed JSA’s for each manufacturing process, implemented weekly safety checklist for team leaders

●Developed, trained and monitored SWI for shop floor employees increasing Quality by 20%

●Team member for ISO-9000 Quality Management System. Achieved certification Feb, 2018

●Cross-training program for the multiple areas' reducing temporary labor while increasing on-time service

●Increased on time service 10% by improving OTD from Suppliers through implementation of first Kanban system that increased communication and improved planning with purchasing

●Implemented daily and weekly TPM activates based on manufacturing recommendations

Wabtec

Plant Manager (September 2007-September 2014)

Responsible for staffing six production areas with a total of 100 employees', permanent and temporary for a multi- technology facility with $80-100 million in annual sales. Duties include create a safe workplace, manpower scheduling, schedule attainment, on-time delivery, quality assurance, and corrective action issues from customers. Schedule preventative maintenance and 5's for 55 pieces of equipment and coordinate and schedule production to support Kaizen activities and champion improvement opportunities throughout production.

Accomplishments:

●Created a flexible workforce that could operate in multiple areas' reducing temporary labor while increasing on-time service

●Increased on time service 10% by improving OTD from Suppliers through increased communication and improved planning.

●Reduced WIP by 25% through Kaizen improvements and Standard Work

●Implemented Safety team and Safety" Walk through Program" to improve on the plant's Safety and eliminate any possible Safety issues.

(November 2004 -September 2007)

QPS Coordinator (Continuous Improvement Manager)

●Held regular Kaizen events (monthly), either in house or at suppliers, to eliminate waste and increase through put by reducing non-value added activities, and improve quality. Approve and specify machine purchases to replace or improve upon current machinery.

●Manage maintenance and preventative maintenance programs for machinery to ensure proper machine utilization. Oversee (1) maintenance manager and 6 maintenance technicians.

●Responsible for the assurance of Quality and output in the manufacturing process through standard work and in-process checkpoint fixtures.

Accomplishments:

●Championed Kaizen activity in an India foundry to improve quality and throughput reduced four days out of process and improved machining fixtures.

●Set-up manufacturing cells and reduced 25% of labor with an increase in through put of 30%.

●Designed assembly area to rework supplier castings improving through put 15%

●Created standard work for all work Cells to reduce Non-value added activities

●Instituted a standard warranty /return system for customers to improve customer satisfaction through faster return of product.

Trendier Components

(November 2001 - September 2004)

Plant Manager

Responsible for staffing four production area's with a total of 100 employees' including union and temporary. Duties included manpower scheduling, schedule attainment, quality assurance, and grievance issues. Handled corrective action issues from customers and scheduled preventative maintenance for 100 pieces of equipment with maintenance personnel.

Accomplishments:

●Maintained 90% on-time service rate with a reduction of 15% man-hours.

●Created a flexible workforce that could operate in multiple areas' reducing temporary labor while increasing on-time service.

Manufacturing Engineer/ Research & Development Manager-

Responsible for process control, process improvements, and cell design for metal stamping, welding and assembly departments. Duties included designing assembly fixtures using AutoCAD, creating work instructions and process flow for assembly, and instituting cellular manufacturing concepts. Also responsible for new product prototypes including: development of assembly labor times, tooling requirements, and establishing new manufacturing process.

Accomplishments

●Established process parameters for manufacturing and process layout with in-process component acceptance criteria for production cell resulting in an increase of through put by 25 % while reducing in-process non-conformances by 15% yielding a higher first pass yield rate.

●Developed standard tooling setup carts used in reducing punch press set up time.

Health-O-Meter

(Nov 1997- November 2001) Manufacturing Engineer-

Responsibilities included: process improvements and layouts, evaluation of production standards, and maintenance to bill of materials and routings for four product lines. Manufacturing processes consisted of 300 employees in the following work centers: hand assembly, punch press, spot-welding, liquid paint line, and testing. Design production fixtures using AutoCAD and managed the ordering of tools for production. Initiate and implement the manufacturing aspects of engineering changes and participated in new product development meetings. Worked with quality assurance on internal non-conformances and with outside vendors with non-conforming materials.

Accomplishments:

●Implemented production cell for a product line resulting in reduced labor of $52,000(2 production operations) a year while increasing productivity of 13%.

●Redesigned packaging for medical line production yielding reduction in material and labor costs by $15,000 annually.

●Set up internal Kanban's between assembly and punch press departments. Established lead times, inventory levels, and procedures to operate within Kanban process. Result was minimized part shortages and reduction in downtime for both departments.

●Involved in an eight-month implementation of an ERP business system (JDEdwards) for manufacturing modules. Supervised three data input personnel in the creation of 600 routings and the cross over of bills of materials. Responsibilities from this project also included the training of end users on the system and residual clean up from the transition.

●Developed standard tooling setup carts used in reducing punch press set up time.

Miller Fluid Power

(May 1996- Dec 1997) Industrial Engineer-

Responsible for maintaining and creating routings for shop floor work orders and developing standards through time studies and updating plant layout.

Accomplishments:

●Designed layout and process flow for Replacement and Accessory Valve production cell.

●Coordinated move and training of operators for cell.

Training

Six Sigma Certification Sunbeam Corporation

Green Belt Certified Wabtec Corporation

Computer Skills

AutoCAD V2004 JDEdwards (ERP)

Mechanical Desktop 3.0 AS400 (MRP)

Microsoft Office Impact (MRP)

Education

Bachelor of Science

Western Illinois University (1996)

Major: Industrial Technology

Minor: Manufacturing Management

References available upon request

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