1. ALAN F. HOOCZKO
1981 N. Stillwater Road Phone: (847) 392-7567
Arlington Heights, IL 60004 ahooczko@wowway.com
CAREER SUMMARY
Accomplished and diversified Engineer & Supervisor with experience in developing Lean Manufacturing processes and
implementing value added activities reducing costs in excess of $400K. This includes Kaizen / cross-functional scrap reduction
initiatives, OEE metrics and TPM activities increasing equipment effectiveness. Also, provided particular expertise in the areas of
project management and capital planning. Comprehensive knowledge of high/low volume mix of metals fabrication & assembly.
EDUCATION
Bradley University, Peoria, IL. (Co-op Program)
B.S. Manufacturing Engineering
PROFESSIONAL EXPERIENCE
Motorola Solutions – Schaumberg, IL 02/15 -
New Product Launch / Contract – Radio & Communication Equipment.
• Supported the assembly, diagnostic testing and final validation for a variety of radio & communication devices.
Abbott Diagnostics - Lake Forest, IL 03/14 – 09/14
Supplier Quality Engineer III (NPL) / Contract – Molded bottle, bottle top, bottle cap, septum & other components.
• Interacted with various suppliers monitoring their effectiveness. This included compiling observations and
analyzing the quality data (Cp/Cpk) for OQ / PQ final validation.
• Coordinated onsite visits to witness and document 21+ new products for their final release to production.
• Participated in prelaunch PFMEA, Control Plan & Process Flow reviews while monitoring CAPA effectiveness
for products in an ISO-13485 and ISO-14971 environment.
Honeywell (System Sensor) - St. Charles, IL 11/13 – 02/14
New Product Launch Engineer / Contract – Smoke alarms, CO2 detectors and Explosion Proof Pressure Switches.
• Interacted with various groups in the timely scheduling, assembly, testing and packaging approvals.
Omron Automotive Electronics - St. Charles, IL 04/12 – 08/13
New Product Launch Engineer (NPL) / Contract – Memory, Easy Entry and Power Door Lock switches.
• Managed NPI deliverables for testing, % yield and final product validation ensuring a 100% effectiveness rate.
• Coordinated readiness reviews, Product Validation’s (PV) and run-at-rate monitoring for final PPAP approvals.
BORG-WARNER AUTOMOTIVE - Bellwood, IL 08/11 – 03/12
New Product Launch Engineer (NPL) / Contract – Friction Products
Managed and supported New Product Launches for the Automotive & Industrial Friction Plate markets. This included Ford, GM,
Chrysler, Cummins-New Holland, Toyota, Caterpillar and Honda.
• Successfully launched (9) programs integrating Control Plans, Process Flow Diagrams, SPC tools & FMEA's.
• Interfaced with Product Engineering, Quality Assurance, team leaders & management to obtain 100% on time delivery.
Target Corp. - Arlington Heights, IL 09/07 - 08/11
Flow Logistics / Assist customers, Load/Unload product shipments, organize inventory and stock incoming deliveries
TUTHILL PUMP - Alsip IL 12/03 - 05/06
Cell Manufacturing Engineer & Supervisor - Flow Pro Products
Complete responsibility for developing machining and assembly processes, CNC Programming, specifying tooling, and
establishing quality procedures and gages.
• Supervised (10) 2nd
shift and subsequently 1st
shift production personnel in the manufacture of “Build-To-Order” Positive
Displacement Pumps for the OEM & processing markets.

2. ALAN HOOCZKO PAGE TWO
• Created +30 std. work & takt time studies in (3) production cells improving the std. cost accuracy/operator efficiency by 40%.
• Improved shaft manufacture by leading a Kaizen team in the development of a Lean manufacturing cell with single piece
flow. This utilized a Studer cylindrical grinder, Haas Vertical CNC Mill and W&S Lathe improving shaft quality & part
through-put from 4-days to 50- min. Also added a new hoist, (2) heavy duty bar stock racks & gage/ tooling cabinets.
• Led a Lean / SMED improvement event creating a multifunction Housing Machining Cell across a family of 6-part types.
This reduced setup time by 35% and throughput from an avg. of (3) days to 55-min. This included (2) Okuma Lathes, (2)
HAAS Vertical Mills, 1-Ton Denison Press, 1- Drill press and deburring station.
BORG-WARNER AUTOMOTIVE - Bellwood, IL 04/94 - 12/03
Staff Manufacturing Engineer & Supervisor – Friction Products
Managed and supported the high-volume manufacture of 190-million automotive & industrial friction plates for Ford, GM,
Chrysler, Caterpillar, Allison, Toyota and John Deere.
• Planned, designed and implemented the $1.4 million overhaul of (3) “friction plate” acid etch dipping lines. This
encompassed new tank designs, material upgrades, contractor coordination & the mandated secondary containment.
• Provided engineering and tooling support for the steel blanking production area improving material handling, safety
and process efficiency, saving +$59,000 annually. This included improved (Herr-Voss) stock leveling equipment, new
(ASC) un-coilers, (QC) collating conveyors and indexing accumulation spindles.
• Created a Lean process flow for friction plate manufacture by reducing process time from 8-days
To 2-days via work cells. This included the use of visual standards and in-line flatness gauging.
• Led several sub-groups in the successful implementation of the TS-16949 Automotive Quality initiatives and ISO-14001
Environmental Certifications. This included 5S, Control Plan, Preventive Maintenance & Set-up instruction audits.
BAXTER HEALTHCARE / REXAM - Mundelein, IL 03/91 - 11/93
Senior Manufacturing Engineer
Supported the 24/7 plant operations necessary to efficiently produce flexible medical packaging. This included vendor negotiation,
project justification, DOE results verification and product launch.
• Prepared sampling observations and laboratory tests for 10+ new products to support the DOE results for a series of
Medical Pouches (ISO-13485). This included destruction testing and water cased ink adhersion trials.
• Produced Value Improvement Project (VIP) savings of $76,000 via Pareto scrap analysis. Upgrades included improved
web processing equipment such as tension controls, servo drives and plastic film treaters.
• Managed the procurement and installation of an Ozone Monitoring System (Oha) that detects & warns of specific ozone
levels in a coating & laminating area. This was an OSHA, EPA and cGMP requirement that successfully avoided
operator injury and illness.
• Researched and coordinated the successful implementation of a Computerized Maintenance Management (Kurtz & Steel)
& Predictive Maintenance System (Entec) that reduced unplanned downtime and maintenance cost by 18%, saving
$43,750 the 1st
year.
Imperial Eastman - Niles, IL Manufacturing Engineer 11/85 – 03/91
Warner Electric - Roscoe, IL Manufacturing Engineer 06/80 – 11/85
TRAINING
Screening Experiment Course (DOE), Conducted by Baxter Healthcare
SPC Train-the-Trainer, Conducted by Baxter Healthcare
Six Sigma Training, (DMAIC) Conducted by Borg Warner
FMEA Certification Review, Conducted by Contemporary Consultants for Borg Warner
CERTIFICATIONS COMPUTER SKILLS
ISO-13485 / Medical Device Excel, Power Point, Word, SAP Data Entry
ISO-14971 / Risk Management AutoCAD, Micros Soft Project, Minitab
TS-16949 / Automotive
ISO-14000 / Environmental