Alan Kastelic

Tooling Manager, 2013 - present Sussex IM is a privately held custom injection molding company specializing in value added automation processes • Procure new molds with annual build budgets up to $5 million and 72 molds. Average budget savings of over 5%. Ownership of specifications for each new mold, from quote to production approval, leading reviews with mold makers and internal staff. • Advanced mold preventative maintenance, repair, and overhaul program. Delegated work order creation to the mold makers for immediate down time notification with IQMS alerts. • Track repair tasks and costing of tool room work using the data to evaluate and improve PM scheduling, future mold designs, and mold handling by technicians. • Cost tracking used to recuperate customer responsible costs, $100K, and develop customer mold repair and replacement budgets • PM program provided process improvements where repair time shifted to PM time resulting in reductions in molding press downtime and tech teardowns / setups. • Establishment and compilation of mold build standards in quick search electronic format. • Created comprehensive DFM (Design for Manufacturing) with reduction in mold debug time and revisions. • Lead project engineers in evaluations of customer product designs. Provide options to achieve efficient product manufacturing. • Led molding floor improvements with training in hot runner systems / controls. Improved safety to people and assets from damage. Purchase new standard of controllers with robust cabling. • Additional molding floor improvement by acquisition of resin moisture analyzer to troubleshoot molding issues. • Won internal contest on improving 5S process having manufacturing teams share in auditing each other. Moved the ownership of the program from management to floor team leads.

1985 Start-up custom plastic injection molder. • A partnership and lead person in the establishment of a new injection molding company from Greenfield to revenue of $3.5 million. • Managed scheduling, quotation, project engineering, quality departments. • Developed quoting/costing system, tooling standards, and the project engineering system.

Dickten Masch Plastics is a privately held custom thermoplastic/thermoset molding company • Front line technical / commercial contact with customers in the development of new business. • Managed six major DMP accounts with total annual revenue over $14 million. • Program management from cradle to grave. • Led teams of designer, quality engineer, sales account manager and tooling personnel. • Assisted customers with product designs and DMP sales in the presentation of quotes. • Directed tool room on repairs and revisions of production molds. • Experienced in directing domestic and international tool build programs. • Led the development TS16949 New Product Development certification received late 2010.

Pentair Filtration is a division of Pentair Water a $3.4 billion-dollar international company. • Account manager leading cross-functional teams in new business development from quote to PPAP approval for the Sheboygan division. • Managed new tool sourcing and repair from RFQ, to production approval. Included supplier selection, mold build with design reviews, mold sampling and debug. • Managed the development of a multi-layer BOM pressure vessel project leading to over $1.2 million annual sales. This included the molds, processing, assembly, and testing operations. • Technical plastic support representative for the NPD group, leading the molding techs.

Polymer Technologies is a plastic injection molding division of MacLean-Fogg, manufacturer of automotive suspension components. MacLean Molded Products was the thermoset division. • Program management of custom projects with external customers using the APQP process from quote to PPAP approval by customer. Cradle to grave from assisting customers in product design for manufacturing to production floor ownership of mold and maintenance. • Management of mold build programs including specifying, purchasing and approval of molds.

Orbis is a $300 million manufacturer of plastic reusable shipping pallets and handheld containers. • Managed annual tooling budgets of up to $4 million. Besides domestic suppliers, qualified international suppliers for both molds and production. • Created mold standards for the structural foam division. Developed and directed local high-pressure injection mold sources in cost efficient methods to build structural foam molds. • Assisted designers with design for manufacturing, automation, and assembly. • Incorporated features into molds to assist with rapid set-up reducing multi-mold setup times from 24 hours to 4 hours. • Championed a team in writing and establishing compliance of procedures for ISO 9001– Design Control. Reengineered practices and trained cross functional groups. • Team member of Green Belt Design for Six Sigma project, which minimized scrap and quality issues during the product development phase.

Polyfab is a privately owned, family organization. • Program management and engineering of custom projects, beginning with design assistance, quotation of product/tooling, management of mold construction and production approval. • Managed tooling build and maintenance programs that involved advancing a mold repair facility into new mold construction. • Supervised four engineering and tool room staff. • Increased customer relationships with revenue growth of over 50% in three years. • Led transition from an owner directed to a team manager environment. • Shareholder and served on the Board of Directors 1993-1994.