Thomas Loonan
Buckingham,IL
Summary
Professionally skilled Foundry Engineer proficient in Product Delivery Process product design, manufacturing procedures/processes, and quality assurance . Have demonstrated great successes working with marketing, product engineering, and other departments to produce successful cast products. Ready to bring 15 years of design and development experience to the Product Delivery Process at a supervisory and mentoring level.
Overview
21
21
years of professional experience
Work History
CCoE FDRY Engineering Lead
John Deere
Waterloo, IA
08.2021 - Current
- Conduct research to test and analyze feasibility, design, performance of cast commodities and processes.
- Conduct feasibility studies for proposed projects, incorporating potential ROI, risk management and other important business metrics.
- Participate in formal internal and external design reviews of proposed products and components, providing input on potential technical improvements.
- Develop work plans for various personnel roles, designing to suit required competencies and technical goals of ongoing efforts.
- Prepare cost estimates, schedules and project specifications for proposals.
- Respond to technical concerns quickly and effectively devised solutions.
Senior Pattern Development Engineer
John Deere
Waterloo, IA
04.2017 - 07.2021
- Assisted in planning of PDP for new product programs tooling builds and testing efforts.
- Conducted/instructed CAD modeling, developed tooling package tolerance stack-ups, integrated failsafe tooling designs to accommodate manufacturing requirements.
- Designed and developed innovative processes to innovate foundry tooling builds for new and existing foundry needs for best production performances.
- Corrected, modified and upgraded foundry tooling to improve performances.
- Coordinated deployment schedule of new product program part releases to ensure departmental successes relative to new product program's MRD.
- Designed, developed, built, tested and deployed highly functioning foundry tooling packages.
- Developed several schemes for new additive manufacturing tooling builds. New equipment provided much opportunity to improve cost structures and reduce lead times from manufacturers initial recommendations.
- Used interpersonal and communication skills to enrich team collaboration through mentoring, improving processes, improving customer relationships for OFP and PDP product delivery, and improving interactions for shop floor operators to become highly engaged in new product programs.
- Developed engineered solutions to CI200 requests and problems to enrich operator engagement.
PDP Strategic Foundry Engineer
John Deere
Waterloo, IA
01.2012 - 03.2017
- Assisted in planning of PDP for new product programs tooling builds and testing efforts.
- Conducted/instructed CAD modeling, developed tooling package tolerance stack-ups, integrated failsafe tooling designs to accommodate manufacturing requirements.
- Designed and developed innovative processes to innovate foundry tooling builds for new and existing foundry needs for best production performances.
- Corrected, modified and upgraded foundry tooling to improve performances.
- Coordinated deployment schedule of new product program part releases to ensure departmental successes relative to new product program's MRD.
- Designed, developed, built, tested and deployed highly functioning foundry tooling packages.
- Developed several schemes for new additive manufacturing tooling builds. New equipment provided much opportunity to improve cost structures and reduce lead times from manufacturers initial recommendations.
- Used interpersonal and communication skills to enrich team collaboration through mentoring, improving processes, improving customer relationships for OFP and PDP product delivery, and improving interactions for shop floor operators to become highly engaged in new product programs.
- Developed engineered solutions to CI200 requests and problems to enrich operator engagement.
OFP Tactical Foundry Engineer
John Deere
Waterloo, IA
09.2009 - 12.2011
- Responded to technical concerns quickly and effectively devised solutions.
- Applied technical/tactical skills and understanding of engineering principles to aid in development of new products, tools and processes.
- Performed quality control procedures on equipment and materials.
- Completed over 75 cost-improving projects consistently sticking to strict schedules and budgets from start to finish.
- Managed various stages of tooling projects.
- Developed engineered solutions to CI200 requests and problems to enrich operator engagement.
- Altered and modified mechanical tooling designs to meet requirements and eliminate malfunctions.
- Conferred with shareholders and supervisors about project progress and explained setbacks to minimize worry and secure project funding.
- Developed and implemented process flow improvement and standardization projects.
Supervisor Mold & Core
John Deere
Waterloo, IA
11.2007 - 12.2009
- To Analyzed test results, machine error messages and information to diagnose equipment problems.
- Set up blow mold and all associated equipment to minimize line changeover times.
- Followed start-up, production and cleaning protocols, as well as completed required logs and documentation.
- Adjusted machine recipes and processes to produce top-quality cast iron products.
- Resolved issues during startup and production while adhering to mold process sequence of operations.
- Collaborated with other leaders and executives to direct workflow and support operations.
- Collaborated with internal teams to streamline operations across materials handling, production and shipping.
- Conducted yearly performance reviews, offering praise and recommendations for improvement.
- Cultivated professional working relationships with peers and supervisors.
- Analyzed equipment breakdowns using various troubleshooting methods.
- Coordinated schedules and reviewed work performance for staff.
- Developed strong relations with company associates, reducing turnover to less than 3%
A200 Quality Support
John Deere
Waterloo, IA
01.2005 - 11.2007
- Reported production malfunctions to managers and production supervisors.
- Cooperated with engineering, manufacturing and corporate accounting to verify adherence to quality standards.
- Collected production samples regularly and performed detailed quality inspections.
- Monitored staff organization and suggested improvements to daily functionality
- Worked with supervision and foundry engineering to realize savings approaching $250,000 by implementing cost-saving initiatives that addressed long-standing problems
Environmental Technician
Eagle Ottawa LLC
Waterloo, IA
07.1998 - 09.2000
- Prepared summaries and charts by testing and gathering samples and summarizing findings.
- Determined chemical composition and nature of industrial pollutants by collecting and analyzing waste samples.
- Worked with site to maintain compliance with applicable environment regulations.
- Performed emergency response activities, tank cleaning and equipment decontamination.
- Collected water samples from semi-processed, processed and raw industrial wastewater.
- Developed and implemented Preventative Maintenance solutions and schedules where audits indicated insufficiencies.
- Prepared samples or photomicrographs for testing and analysis.
- Directed activities of workers in laboratory.
- Performed statistical analysis of environmental data.
- Drove operational improvements which resulted in savings and improved profit margins.
Production Supervisor
Eagle Ottawa LLC
Waterloo, IA
10.1996 - 07.1998
- Trained staff of direct labor employees to perform operations and manufacture of specified products.
- Prepared in advance for and addressed production problems, material deficits, equipment failures and unavoidable delays.
- Utilized lean practices to balance workflow and alleviate redundancy.
- Achieved on-time shipments goal by empowering employees to continued success.
- Oversaw equipment modifications and upgrades.
- Set and enforced performance-oriented production approach, significantly increasing worker output and reducing safety incidents.
- Established clear priorities and production quality standards.
- Compiled production equipment status reports, detailing parts produced, downtime duration and potential quality concerns.
- Supervised work on bestselling, industry-leading products.
- Resolved issues quickly to maintain productivity goals.
Education
Associate of Science - Industrial And Municipal Wastewater Treatment
Kirkwood Community College
Cedar Rapids, IA1999
Skills
- Product development
- Process development
- Production design
- Digital design
- Production understanding
- CAD proficiency
- 2D and 3D modeling
- Project management proficiency
- Budgeting
- Technical diagram generation
Accomplishments
- Awarded Patent P25840 through effectively teaming with design, marketing, manufacturing, quality, processing, and sales to develop a new cast geometry that yields a cast product with expectations of >$1.5M annual savings/cost avoidances.
- Developed new additive manufacturing soft tooling build by collaborating with team of ≤15 in the development of foundry engine block feasibility study/build.
Camping, Fishing, Hunting, Mt. biking
I am an avid outdoors person. While these activities are of my most favorite, I'm typically interested in most activities that keep me out of doors
Timeline
CCoE FDRY Engineering Lead
John Deere
08.2021 - Current
Senior Pattern Development Engineer
John Deere
04.2017 - 07.2021
PDP Strategic Foundry Engineer
John Deere
01.2012 - 03.2017
OFP Tactical Foundry Engineer
John Deere
09.2009 - 12.2011
Supervisor Mold & Core
John Deere
11.2007 - 12.2009
A200 Quality Support
John Deere
01.2005 - 11.2007
Environmental Technician
Eagle Ottawa LLC
07.1998 - 09.2000
Production Supervisor
Eagle Ottawa LLC
10.1996 - 07.1998
Associate of Science - Industrial And Municipal Wastewater Treatment
Kirkwood Community College