Paul Neblock 
Associate Consultant 

Paul Neblock

Mr. Neblock has a career that spans over four decades in manufacturing and consulting. He has unique abilities to: make the complex simple, identify automation opportunities in manufacturing operations, identify and mitigate process risks for capital projects, and solve complex problems – including rescuing large capital projects that are not performing. His expertise in injection molding and blow molding includes equipment specification and acquisition/implementation, automation for machine tending and secondary operations including assembly and testing, and improving OEE in tough (24x7) manufacturing settings. He has the ability to lead teams, involve all voices in problem solving, and engage with all levels of the organization to identify and implement change. He focuses on significant operational improvements (breakthroughs) and the use of advanced technology including automation to improve throughput, operational efficiency, and quality.​

PROFESSIONAL EXPERIENCE

2018 - Present
Independant Consultant   
Martinsville, IN

Founder and practitioner in consulting firm providing customized services to manufacturers to improve productivity, OEE, throughput, and quality through the proper use of automation, “smart manufacturing”, breakthrough process improvements, across multiple industries and processes. Active participant and leader in project and company turnaround efforts in a wide range of industries.

• Assisted a division of Fortune 500 electrical products business with a launch of a new line of injection molded enclosures with integral seals. Provided DFM/A input to the design, developed automation scope of work, sourced equipment, provided cell layout, reviewed quotes, and developed budget for the project. Coordinated process testing.
• Worked with a small electrical plug manufacturer develop a concept and quotes for automating screw insertion for high volume plug assemblies. Simple mobile work cell to be moved between injection molding machines.
• Active in OEE improvement for a large Tier I automotive supplier of under the hood air and fluid management components and assemblies. Analyzed downtime and scrap data for a large number of blow molding and injection molding cells (including secondary operations), prioritized corrective actions, and led efforts to systematically reduce scrap and machine downtime. Observed machines and cells in operation to identify chronic issues and direct rapid maintenance and corrective actions. Directed actions of repair technicians, tooling repair technicians, and process development personnel.
• Conducted in depth OEE assessments for injection molding and plastic extrusion firms (large pipes) to develop comprehensive plan to improve equipment uptime, throughput, and safety. Multiple plants and locations. Evaluated maintenance systems, skills, and use of CMMS.
• Assisted numerous other firms in the automation journey:
  • Identifying and prioritizing automation targets within their operation
  • Sequencing projects to obtain maximum ROI
  • Assessing maintenance, tooling, and support operations to enable automation
  • Write scopes of work for automation projects, identify and qualify vendors, and as needed manage large project implementations - $1M to $5M
  • Evaluating failed projects that were failed and identifying practical solutions to make cells work
• Worked with multiple firms in other industry verticals including aerospace, large extruded pipes, overhead door systems, to improve OEE, plan and implement capital projects, and in some cases act as interim manager of Maintenance, CNC Programming, and Tooling for aerospace Tier I to Lockheed Martin.
• Developed unique processes for manufacturing titanium extrusions to virtually eliminate residual stress.

2017 - 2018
Suncast Corporation - Director of Automation  
Batavia, IL

Organized, led, and developed team of engineers and technicians to support large 24x7 injection and blow molding operation for very large producer of consumer products (>$1bn in Revenue). Provided hands-on help to teams to solve complex process and automation challenges, develop and launch new products, and develop cost reduction solutions. Managed tool room and maintenance of all automation projects – robots, EOATs, special machines.

• Led the technical debugging of a large blow molding cell for trash containers with insert molding, six-axis robotic part removal, cooling, trimming, inspection, and packaging.
• Led the de-bugging of large packaging cell that included cartoning, shrink wrapping, labeling, and palletizing large blow molded storage sheds (400 lbs. per carton).
• Improved throughput and efficiency in the high-volume injection molded hose reel line through thorough analysis and re-balance of the line, rearrangement of injection molding machines.
• Resolved chronic downtime in complex assembly and leak testing equipment for high volume insert molded hose fittings.
• Evaluated numerous failed automation projects and developed practical solutions to resurrect them – most due to lack of molding process control and poor concepts in trimming.

2015 - 2017
Alfa-Laval – Unit Manager of Engineering 
Woodale, IL

Led and managed engineering design, manufacturing engineering, and maintenance functions for company that designs and builds shell and tube heat exchangers. Reviewed designs, streamlined design process and improved product manufacturability, led structured problem-solving process, and improved equipment OEE for complex robotic equipment in shell and dome cutting.

• Reduced product design and detailed lead-time for custom vessels by 50%
• Improved OEE in some critical processes: cutting vessel shells on robotic plasma cutter, and cutting holes in domes with robotic plasma cutter

2012 - 2015
TC Industries – Manufacturing Engineering Manager 
Crystal Lake, IL

Managed and led team of manufacturing and industrial engineers to introduce new products, reduce costs, eliminate scrap, and improve throughput for this Tier I supplier to Cat. Identified and implemented automation projects and use of smart technologies.

• Rescued complex robotic welding cell for bucket edges
• Conceived of and implemented CNC plasma cutting cell for small components - $100K Savings per year
• Utilized part family analysis to drive improvements in throughput and productivity- reducing costly changeovers and scrap - $250K per year
• Organized and managed cutting tool crib for the shop and optimized CNC cutting processes saving - $200K per year

2009 - 2012
Plymouth Tube Company – Advanced Operations Consultant
Multiple Plants – Six

Supported the operations of six focused plants manufacturing stainless steel tubing for specific market segments by identifying and implementing breakthrough operational improvements (those with rapid significant return). Researched advanced technologies across the US and Europe to find suppliers and techniques to solve specific challenges and provide a competitive advantage.

• Developed and implemented comprehensive OEE improvement methodology involving a detailed assessment, machine refurbishment, data driven PM and use of CMMS 
• Identified and implemented advanced welding technology for welding thick-walled tubing to increase throughput by 50%
• Developed advanced technology to hot stretch titanium extrusions rapidly and with low residual stress – resulted in additional $20M in revenue

 2003 - 2012
Independent Consultant 
 Ann Arbor, MI

Founded and grew manufacturing consulting practice for a wide variety of companies in different market niches including: automotive parts, lawn and garden equipment, custom trucks, tubing manufacturing. Worked with injection molding firms, fabricators, and firms of all sizes to improve productivity, OEE, embrace automation, and reduce costs.

• Identified and implemented die treatment methods to increase life >200%
• Conducted plant wide assessments of facilities to identify and prioritize improvement opportunities – developed improvement roadmaps and led large projects in plant layout, new capital equipment acquisition, set up reduction, Lean implementation
• Developed multi-year capital equipment plans to support growth and the introduction of new technologies
• Introduced key performance indicators (KPIs) to drive improvements – Balanced Scorecard

Prior to 2003
Various Management and Consulting Assignments
Wisconsin, Illinois, Michigan

Lead manufacturing engineering teams for large consumer products (Newel Rubbermaid) facility and automotive supplier (Exatec) – new product development, capital equipment planning and deployment, resolution of process issues. Injection molding, printing, flocking, assembly, packaging automation for a wide variety of products. Implemented automation ranging from simple pick and place to six axis robots to remove parts from molds and for downstream assembly and packaging.

Learned Consulting business at Grant Thornton, LLP in WI where I worked with a wide variety of clients across the Midwest to improve flow, enhance productivity, introduce new products, and improve OEE. Implemented Lean and ISO0991 quality systems.


PUBLISHED ARTICLES 

• “How Process Variability Kills Automation” – The Fabricator, May 8, 2023
• “How Automation and Lean Manufacturing Go Together” – The Fabricator, April 15, 2021
• “How Fabricators Achieve Breakthrough Improvements” – The Fabricator, December 5, 2020

ADDITIONAL SKILLS

• Project Management – from PMBOK Training Sessions
• World Class Maintenance
• Microsoft Office Tools
• Consultative Selling
• Change Management
• DFM/A, PFMEA, FMEA, PPAP, DMAIC, 8D, 5S, SMED

EDUCATION 
Master of Science: Nuclear Engineering
University of Illinois – Urbana, IL

Bachelor of Science: Physics
University of Illinois – Urbana, IL

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