Tom Stone Email & Phone Number

Oconomowoc, Wi, Us

Waukesha, Wisconsin, United States

Waukesha, Wi

Working closely with the operations teams and IT staff, research and implement new technology in manufacturing operations.Managed project to implement custom software for tracking serialized machined housings through machine shop. The software is a .net application that reads / writes to a HUSCO designed SQL relational database to assure parts have met all quality and audit steps required in the control plan.Implemented SQL database for data analysis of CMM data collected in the machine shop. Developed Quality inspection (Tollgate) program that combined data sources of our manufacturing and business system databases for the first time at Husco. This system is currently being used in three sites in the U.S. and India.Developed multiple manufacturing dashboards and data mining tools for engineering using Power BI. Collaborated with HUSCO BI team for more advanced queries and data analysis.

Waukesha, Wi

2010-2016Worked with HUSCO's facility in Pune, India to improve operations quality and launch new products for key customers. Provided tooling, quality and process improvement projects, and new manufacturing assembly equipment to successfully launch new products. Traveled to India six times over this period. 2013 - 2014Supported operations in HUSCO's China facility, part of a team to install new equipment in the facility and launch new programs for key customer. 2015-2016Worked with HUSCO software supplier to take a concept of AMS (Advanced Manufacturing System) from concept to production in our China facility. The system integrates with a HUSCO designed database and connects to various manufacturing equipment to mistake-proof manufacturing operations. The system was able to make dramatic improvements in customer quality. This system was adopted by other sites and is now in place in four HUSCO sites and 18 assembly lines.

Waukesha, Wi

2005 - 2007Implemented new concept assembly lines in Waukesha which drastically improved quality, ergonomics, and lead time. This line included modular mounting fixtures for flexibility for new products, a creative machine design for rotating heavy parts, and custom honing and wash equipment. Implemented epoxy paint process and equipment in Waukesha facility. This system, along with improved pretreatment and monitoring, improved corrosion resistance from 24 hours to over 400 hours in a salt spray chamber.2008Designed and installed new 3-stage pretreatment system in Waukesha facility paint line. Added control of dry-off oven to washer controls which eliminated outdated controls. 2008-2009Designed, justified, and managed project to install large paint line in new Maquoketa, IA facility. The project was the first equipment to be installed in the new facility so I spent extended time working with local contractors to manage the implementation with little support. This paint line expanded capacity for three U.S. sites. Product from two facilities was painted in Maquoketa utilizing only one shift. This eliminated a bottleneck operation in Waukesha. Part of a team selected to start up new HUSCO facility in Maquoketa, IA. This team was able to lay out the facility and move six assembly lines to the facility in 18 months.2016 - 2017Selected as a team member to transfer remaining manufacturing operations from Waukesha to our facilities in Maquoketa, IA and Whitewater, WI. Used this opportunity to expand AMS opportunities on lines that were re-located.

Greater Milwaukee Area

Led a team of Mfg engineers that supported rubber injection molding and assembly operations for the transformer components division.Implemented a PLC network for molding presses to save current parameters and reduce scrap on set-up. The network was used to download and save best settings to each press.Part of a scrap reduction team that reduced scrap from $3M to $0.95M annually over a three year period by taking a wholistic approach. Training, lean six sigma analysis, tooling and process improvements were all a part of the program.Creatively addressed short term capacity by working with equipment supplier to lease new machines. This addressed an immediate capacity need without needing to implement capital. When demand did not taper off we were able to purchase the machines at a reduced rate.Managed intense efforts at re-sourcing components to Asia, and doing testing and prove out in manufacturing.Trained and implemented six sigma projects to reduce WIP inventory and scrap.

Greater Milwaukee Area

Supervised 11 hourly people in two departments. Indirectly supervised 2nd and 3rd shift operations. Implemented kanban on sub-assemblies in my department which completely eliminated a bottleneck operation. Found ways to improve capacity while maintaining WIP. Led ergonomics team and implemented over 30 ergonomic improvements throughout the shop.

Greater Milwaukee Area

Part of a small team charged with implementing lean manufacturing in a traditional manufacturing environment. Designed and implemented cellular manufacturing cells which drastically reduced WIP, decreased throughput time, and improved quality. Trained hourly and salaried personnel on lean manufacturing to assure responsible change management.Managed capital projects for machining operations. Justified and installed a VMC which reduced machining cycle time of aluminum castings by 30% by implementing improved programming, tooling, and rapid travel. Designed flexible fixturing to enable quick changeovers necessary for shorter lot sizes.