Rob Mohr IE/Mfg Engr December 2006
Current: Box 2063, Davenport, IA 52809-2063 309.631.6073 robmohr@earthnet.net

CBT/Modern Rochester Hills, MI 48307 March 06 - November 06 Contract assignment tasked to Deere Dubuque per an industrial engineering project.

STROM ENGINEERING Minnetonka, MN 800.205.8732 Dec '04-April '05 Contract assignment at Case New-Holland backhoe assembly plant Burlington, Iowa. Tasked to Quality Control Dept with primary duties being material dispositions, quality control reports on line rejections, quality control audit sweeps. No Time & Motion studies as part of duty.

GE-PLASTICS Denver,CO Jan '99-March 2001 Architectural detailing for approx $ 2 million of projects per annum. Additionally, set up, hand coded, cgi, company website to disseminate and collect info. CAD, autocad 14, wireframes, pspace, mspace, SolidWorks, CNC g-m-codes, Lean/Agile techniques, Time studies of about 10% of task duty to verify planned manufacturing process changes, typically on the CNC router tables.

STANLEY AVIATION CORP. Denver, Colo Oct '97-June '98 Manufacturing routing for Douglas, Boeing, Gulfstream, & Sikorsky airframe parts & subassemblies. Development of bill of material, process routes, work order instructions, material disposition & finishing operation with respect to in house process specs , Mil-Specs, and specific air manufactures' requirements. Lead the design of a hydraulic circuit to fail-safe a Teledyne-Pines bender from having a tube mandrel up-set. (This upgrade removed the risk of multiple thousands in annual repairs, not counting production down time, and removed the risk of harm to the operator.) Time & Motion studies comprised about 10% of duty tasks via stop watch and board. Stanley Aviation is now owned by Cobham PLC, an English company. Cobham recently purchased the former Bendix, former Grumman-Northrup Life Support Systems in Davenport, Iowa.

AUTOTRON Longmont, Colorado July '97-Oct'97 1.800.525.3052 Automotive organization producing from multiple plants auto parts for OEMs as well as the aftermarket. Initial project focus to consolidate hardware and fastener kiting at a service center. Follow on project to develop new rock guard for class 8 trucks. Kaizen methods employed, industrial engineering techniques and analysis used, budgets & reports to district management. Time and Motion studies were used as a tool for building up the data for the hardware consolidation project.

SASIB PACKAGING, Skokie, IL Contact: Norm Buggele 847.677.7800 Sep '95 - Jan '96 Sasib Packaging is an Italian owned organization that builds custom packaging equipment that is able to both meter and film package both dry and liquid product. Major duties included estimation of labor, material, set-up, and tooling costs for both inhouse fabrication as well as outside buyouts. Mechanical parts typically are aluminum stock sizes that receive three to ten machining operations and a finish of clear anodizing. A second line of packaging equipment will open, fill, and glue shut carton boxes; for example, Sasib recently delivered a cartoning machine for filling MilkBone dog biscuits. Directed several projects that yielded order of magnitude improvements in the manufacturing process. Item: Top end plate for cartoning machine, was $ 2500 and now is $ 250 plus some inhouse machining operations. Item: Heater rolls were $ 35,000 and now are $ 3500. This improvement to the profit margin or the increase in market share via competitive pricing was achieved by changing from a pure 100% machining process to an aluminum extrusion process. Item: Improved operating margins by using derivative calculus to optimize the fab to stock quantity for both inhouse and outside fabrication buyouts. Item: Reduced the total part count as well as assembly input by moving from a pure mechanical drive to a PLC electronic drive. Final machine performance improved in several parameters due to this design change. Item: Using stress-stress analysis the main gearbox weldment for the cartoning machine was engineered to match section properties with actual loading. Also, changing from rigid to flexible couplings resulted in reduction of required machining and improved location constraints. Item: Put forth the argument to electrical designers to move from a hardwired approach to a more current data bus design with respect to sensoring and controlling the machine elements. Client computer equipment used: HP-3000 and PC network; computer software used, JobScope, ME-10 (lightly.) Contract via ESPO Engr'g Contact: Bill Hearne 630.789.2525

READY METAL Mfg. Chicago,IL July '94 -Sep'95 Contact: Mark Kedzierski, Len Lowkowski, or Ron Maruzak. 312.376.9700. This organization is a 40 year old family business with about 350 people on payroll, and the main focus is sheet metal fabrications that are used as store fixtures for Sears, Firestone Tire Retail, Circuit City, and B. Dalton Book stores. Ready Metal has been a longtime supplier to Sears stores and until recently Sears was a large fraction of the total business mix. Ready Metal issued a callback to me from a previous stint as a contractor via ESPO engineering. Ready Metal bought out the contract to take me direct. Major duties centered on process routing for new business. Process routing takes finished or rough sketches from the fixture designers and calculates the stretch out for shearing, laser burning, turret punching, and then takes the process through brake forming, resistance and mig welding, and the process ends up with a powder coat finish. Some process route sheets detail sub and final assembly procedures. Material cost, labor inputs, tooling, special buyouts are areas that get attention during the fabrication process task. Typical production runs were in the hundreds of pieces with some very large orders as well as small orders. Production quantities would severely impact the actual process sheets, but run quantities were not always known in advance. This lack of information as well as late design changes due to customer and manufacturing requirements generated a healthy flow of ECNs for the process route sheets. Item: Introduced using .DXF file transfer via the internet to speed the production of special and time critical off-site part fabrication. Item: Changed design spec from weld-paint-assemble to an abridged process of paint-assemble using 3-M structural adhesives with attending operation margin improvements with respect to material and labor inputs. Item: DFM (design for manufacture) methodology guideline for the fixture designers to work closer to the actual fabrication route sheets. Time Studies and Motion Analysis were used to aid the build up of process routing sheets for part fabrication including shearing, CNC turret punching, press brake forming, resistance welding, and painting. Stop watch and time study would be about 70% on the initial contract project and about 20% on the second call back assignment. Computer equipment used: AS400, PC, some limited time on a Digital Alpha workstation running 2-D Applicon Bravo. Placed via Espo Engr'g.

FASHION BED GROUP Chicago, IL Oct '93 -Jan '94 Contact: Mfg. Manager 708.458.1800 FBG is a manufacturing division of Levitt & Levitt that mass produces metal bed frames that are sold both through main line retailers such as Montgomery Wards as well as through an extensive network of single niche retail stores called the Bedding Experts. The Chicago facility at this particular time changed over to a cell fabrication organization that made over 1500 frames per week with people divided into teams of 5-6 individuals. Some production came from the Far East to stateside in shipping containers. Most of the production was for domestic consumption; however, a growing fraction of FBG went into export sales to Latin American markets as well as Far Eastern markets. Duties centered on work measurement for cell fabrication teams. Item: Oblique angle tube cut-off equipment for flush weld finish. This fabrication change improve both appearance as well as minimized weld input and eliminated weld grinding effort. Contract assignment via Technipower. Time & Motion Study for this assignment involved about 50% of task duties.

READY METAL Mfg. Chicago, IL April '93 - Aug '93 Contact: Chet Sambor Work measurement for new and old fabrication operations. Tasked to work measure via board and stopwatch MIG, TIG, and resistance welding operations. Typical production rates were .80 - 2.50 Hrs/C pcs. Contract assignment via ESPO Engr'g. Time Study for this assignment was about 70% of duty.

PRATER INDUSTRIES Chicago, IL Nov '90 - Dec '92 Contact: Jerry Wroblewski, Col. John Potter, Kirsten Ellison, Scott Prater 708.656.8500 Prater Industries is a 75 year old family business that has several lines of hammer mills and fine grinders for the industrial and agricultural markets. Typical customers are ConAgra, Central Soya, General Mills, and Quaker Oats. They also have a declining product line of rotary feeders, (air locks). While the product lines are rather old designs, each new order will require a fair amount of custom engineered features to suit the intended process line requirements. Duties ran the range of general purpose manufacturing engineering with about 10% workmeasurement, 30% order entry, 30% projects, and 30% "firefighting" duty. Item: Directed a shop inspired redesign of a quick release clamp mechanism for the MegaMill product line. The design went from about 24 separate parts in the assembly to about six distinct parts. Resulting improvements in cost, performance, and maintainability added to margins and protected market share. Item: Received approval of a redesign of a process declumper mixer from 48 separate welded components to a 4 piece mechanical assembly with 8 plasma burned blades. This design gave an order of magnitude improvement in manufacturing cost as well as yielding mechanical performance improvement. Custom engineering per order became an option with this design that resulted from a DFM (design for manufacture) idea. Item: Manufacturing process change for a compactor auger that yielded an order of magnitude cost reduction from $ 8000 to $ 800 with no degradation in function and an anticipated improvement in field reliability, ( elimination of a nettlesome machine warranty problem.) Item: Directed the office and shop effort in the rebuilding of a 100 ton capacity briquetting machine. (The Timken bearings weighted 60 lbf each!) Item: Used precision investment casting to replace a CNC machining process for the briquetting dies and thereby achieved a workaround that kept the fixed-price contract on budget. Item: Per sketches, fabricated a demonstrator heat exchanger for use in browning food spices. Direct employee. Time & Motion Study took up about 10% of the task duty.

The GEORGE EVANS CORP. Moline, IL Oct '87 - Nov '90 direct employee. Contact: D.W. Evans 309.757.8300 GEC is a 75 year old family business that produces cable toroidal shipping reels. Toroidal reels are the metal, returnable reels that serve the same function as the one-way wooden cable reels. Duties were about 25% work measurement for a shop incentive program, 70% sheet metal quotations, and 10% g-coding. About half of the business was toroidal reels and the other fraction being contract sheet metal fabrication for JI Case, Deere, Bandag, Parr Instruments, and Montgomery Elevator. Basic sheet metal operations such as shear, punch, form, and weld. Item: Mocked up a square stacker cable reel. Item: Hand built two composite reel flanges, 36" diameter, using an innovative material from 3-M. Item: Researched and found the original Western Electric patent for toroidal reel construction. (GEC had a twenty year exclusive license from Western Electric to build the cable reels, circa 1936-1956.) Item: Submitted to the owner a proposal to build a modular die for forming custom toroidal flanges for the fiber optic market. Current tooling follows decades old standard sizes. Item: Advocated the use of finite element analysis to value engineer the cable reel product line with the intention of gaining market share or increasing margins. Item: Lead project effort for installing a gas-plasma profile burning cell for producing CASE IE combine fan shrouds per an accelerated schedule. ( Case had fiberglass shrouds cracking and failing out in the field.) Item: Using engineering cost analysis methods, the chief engineer was persuaded to use a then new laser cutting process instead of standard hard tooling for an prototype to production quantities order from CASE IH for alternator brackets. (This was an ECN per the fan shroud change, and the manufacturing change to a laser process won the competitive bidding as well as increased the owner's profit by $ 14,000.) Time & Motion Studies were about 25% of the duty tasks.

FIRESTONE TIRE & RUBBER Co. Des Moines, Iowa July '81 - Oct '83 (This company was bought out be the Japanese owned Bridgestone Tire Co. a number of years ago. About circa '87. At that time the Des Moines Firestone Tire Plant was the largest within the company both in square feet manufacturing space as well as number of people 1,000,000 and 1,800 respectively. Due to a union contract change the whole plant was open to be work measured. Duties, 100% work measurement with watch and board. Item: Watched weekly ratings films to aid in the measurement effort. Time & Motion Studies in a bullpen with six other industrial engineers involved 100% of the task duty for this job.

Passed Iowa EIT (engineer-in-training) now know as "Fundamentals" Jan '82. Contact: Iowa Board of Engr'g Examiners, Ankeny, IA; pulled 66 score on IL Mech PE exam, '93. IOWA STATE UNIVERSITY Ames, IA BS Engineering; major, IE; minor, ME. Contact: Beardshear Hall for transcripts. Aug '77 - May '81 ===========================================================================