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Thomas Hornyak

Manufacturing Process Engineer

Jamestown, NY


Thomas J. Hornyak 
3017 Garfield Road #6D 
Jamestown, New York 14701 
(716) […] 
Professional Experience 
12/2011 – Present 
H&H Aero’s Manufacturing Process Engineer 
Producing Aircraft Quality Fuel Nozzle components for new fuel efficient GE, BMW, Rolls Royce Aircraft Engines is an amazing challenge. These components made from high temperature and tensile strength materials such as Haynes 188, Hastelloy X and Inconel 718. These materials alone are difficult to machine. Product designs are intricate, complex and require avid attention to exacting dimensional and geometric tolerances. 
Provide professional and mentoring support to develop operators’ skills and abilities as the business is experiencing rapid growth. Introducing Lean procedures i.e. Standard Work, Value Stream Mapping, 5S’, 5Whys to facilitate process efficiencies and consistency. Many of our components are on Kanban with new additions regularly. Responsible for new equipment specification, acquisition, installation, start up and training.

Work Experience

Off Highway Vehicle Advanced Manufacturing Engineering Services Support Manufacturing Engineer

GE Transportation
Erie, PA

August 2011 to November 2011

GE Transportation OHV Advanced Manufacturing Services Support Manufacturing Engineer using lean and 6 sigma methods to facilitate throughput and transform machining and assembly operations to “pull system”. Division is in ramp up mode adding capacity in order to meet customer demand for GE Transportation produced AC & DC electric motor transmissions and control systems used exclusively in the mining industry.  
Current Project; Assist in CNC Program updating from ADAPT IV programming language to MasterCam X3. Consolidating and standardizing CNC machine tooling and reprogramming to MasterCam (still developing MasterCam X3 skills) for Lathe and Mill

Teksid Resident Representative to Cummins Jamestown Engine Production Facility

Teksid through Superior Technical Services
Lakewood, NY

March 2011 to July 2011

Teksid (Brazil and Mexico plants) Engineering Representative employed through Superior Technical Services located at the Cummins Jamestown Engine Plant. Acting as on-site liaison, monitoring and documenting quality and compliance issues with Teksid supplied Engine block and Cylinder head castings. These components are machined, assembled, tested and shipped worldwide from the Cummins Jamestown Diesel Engine Plant.

Unemployed / Searching for work (2nd)

New York State Department of Labor
Jamestown, NY

October 2008 to February 2011

Searched for and applied to countless positions across the United States where I considered myself a “good fit” based on my qualifications and experience.

Production Turning Operations Manager

Innovative Tool and Machine Company Inc
Falconer, NY

October 2004 to September 2008

Innovative Tool and Machine Company, Falconer New York successfully produce a new business segment, supplying precision Automotive and Aerospace bearing components to SKF Aeroengine N.A. 
Please note: ITM closed first quarter 2009.

Unemployed / Searching for work (1st)

New York State Department of Labor
Jamestown, NY

March 2003 to October 2004

Never having been unemployed before I searched for and applied to countless positions across the United States where I considered myself a “good fit” based on my qualifications and experience.

CNC Engineering Supervisor

SKF Aeroengine North America 1 Maraco Road
Falconer, NY

January 1989 to March 2003 
Supervise 3 salaried CNC Programmers; provide hands on support for 40 CNC machines producing precision bearing components for Aviation Aerospace and Commercial applications 
Project Management 
• Drive work flow through the entire department 
• Capital project ($6M), procure 10 new CNC machines using cross-functional teams 
• Member of Team driving Total Productive Maintenance (TPM) and performing Kaizan setup time reduction events to improve equipment up-time  
Process Development 
• Re-tooling CNC Machine centers and achieving on average 70% cycle time reductions 
• Turning Carburized and Hardened materials 
• Hard Thread milling RC50 M50-nicklel (M50-Nil) 
• Advise Product Design Engineers to incorporate product manufacturability (DFM) into new products

Senior CNC Engineer

Teledyne CAE Gainesville Division
Gainesville, GA

January 1986 to January 1989

Transfer and support Williams International F107 (Cruise Missile engine) and Teledyne CAE J373 (Harpoon Missile engine) manufacturing, assembly and test operations from Toledo, Ohio facility to brand new facility in Gainesville, Georgia. 
Please note: The Gainesville facility closed in 1993 and moved back to Toledo

Senior CNC Engineer

Teledyne CAE Toledo Division
Toledo, OH

November 1981 to January 1986

CNC machine programming and hands-on manufacturing support for CNC Lathes (2 & 4 axis), Machining Centers (3, 4, & 5 axis), and CNC Internal & External grinders. Machining high temperature and light weight metal alloys. 
I left the Toledo division as member of 14 person new plant start-up team.

Manufacturing Engineer

Easco Hand Tools
Springfield, MA

March 1980 to November 1981

Produce ratchets, sockets, extension bars, hex keys etcetera for Craftsman, Easco, and Master Mechanic Customers. 
I left Easco for a better career opportunity.


B.A. in Engineering and Management

Western New England College -
Springfield, MA

Additional Information

Professional Skills 
• Design and specify: processes, methods, fixtures, gages & tooling 
• Design for Manufacturing (DFM), Geometric Dimensioning and Tolerancing (GD&T) 
• Work and communicate effectively with all organization levels, customers, and vendors 
• Long-time champion in cost reduction, process and work-flow improvement. 
• Excellent deductive, quantitative, analytical and problem-solving skills. 
• use metrics to validate improvement goals 
• Manufacturing environments; high mix / low volume and low mix / high volume, high-precision, complex, intricate. 
• CNC multi-axis lathes (conventional and Swiss style), mills 3,4&5 axis, ID/OD grinders; tool up, provide fixturing, program, setup, train, and operate, total productive maintenance (TPM) 
• Micro Soft Office, MasterCam, Esprit, Compact II, Part Maker, VMS, XLNT, CAD, CAM, McAuto