1. Sean Costin
708-528-0992 • Arlington Heights, IL 60004 • scostin333@gmail.com • https://www.linkedin.com/in/sean-costin
Operations Management
PROFILE
Achieving manufacturing success through hands-on interaction
Leading in lean manufacturing and continuous improvement culture
Driving next-level productivity through technology integration and automation
SKILLS
Operations Management | Personnel Management | Project Management | Lean Manufacturing
ISO 9000 Quality Management | Continuous Improvement | Sales Engineering
Business Development | Strategic Planning | Compliance | Engineering | Automation
ACCOMPLISHMENTS
● Surpassed all company divisions on profit and efficiency on an annual basis for 20 years.
● Achieved 75% cost reduction through a project to manufacture two essential supplies in-house.
● Transformed manual jobs into profit superstars with automation - increasing production by 1500%.
● Expanded capabilites by 700% on a single machine by driving equipment design improvements.
● Secured a battery sealant business by leading a team to improve a process that tripled speed.
● Earned near 100% customer satisfaction ratings by utilizing ISO 9000 system and corrective actions.
● Launched 20 new coatings on the production floor. Directed quality, training, process and execution.
PROFESSIONAL EXPERIENCE
ND Industries Northbrook, IL 1/2001-11/2019
Operations Manager | Assistant General Manager
Managed 30+ employees in a muti-site processing division of a 50MM+ company specializing in pre-
applied fastener thread-locking and specialty chemical coatings. Oversaw production, engineering,
personnel management, process improvement, new process development, business development,
purchasing, maintenance, facilities and divisional IT.
Planning and Strategy
• Developed strategic plans for operations focused on delivering results for productivity, quality, safety,
on-time delivery and training. Turnaround time on orders reduced by 45% in 2019.
• Created strategic plant layouts for equipment, utilities, process cooling, ventilation and lighting which
addressed OSHA, EPA and hazardous materials regulations.
Productivity
• Developed KPI’s and efficient collection methods to analyze performance on a job to job level which
created daily indicators of production and pricing problems.
• Applied quick-changeover ideas: replaced inefficient part feeding systems and automated feeding
controls which reduced setup times in a range of 25% to 200%.
• Instituted FIFO inventory management which prevented shortages and reduced chemical waste.
• Created a preventative maintenance program which reduced unscheduled downtime and reduced
outside repair costs by~30% over the last 5 years.
Engineering
• Developed new coating methods for high-speed application of adhesives and sealants resulting in
significant sales growth in new market segments with margins that averaged~35% higher
• Designed new processing equipment with external engineering and fabrication sources reducing
engineering costs. Design improvements reduced the need for tools and cut set-up time.
2. (Page 2) Sean Costin • scostin333@gmail.com
Personnel Management
• Hands-on involvement in plant operations earned cooperation from organized labor and facilitated a
culture shift toward customer focus.
• Coordinated with human resources to control insurance costs through compliance with DOL and
EEOC regulations.
• Received zero OSHA complaints in last 10 years after instituting regular safety meetings to emphasize
company concern and quickly reconcile employee complaints.
• Negotiated 7 - three year union labor contracts without labor stoppage. Secured a favorable
agreement for insurance on new employees. Held wage costs in line with comparable companies.
Project Management
• Directed plant startup-Rockford, IL and integrated a purchased business.
• Integrated 15 new production lines and major facility infrastructure improvements. Updated older
machinery and realized 400% increase in capacity over 20+ years.
• Managed electric, gas, machinery updates-saving thousands on engineering for every project.
Information Technology
• Developed a flexible in-house mini ERP system to manage and unify sales orders, documentation and
process control saving a minimum of $300,000 in software over 20 years.
• Led a cross-functional team to implement an automated scheduling system to enhance control of
operations and automatically locate opportunities to save setup time by grouping similar parts.
Quality Manager (last 10 years -concurrent position)
• Assumed complete control of quality system and staff which reduced annual office payroll by $20,000.
• Instituted a new ISO 9000 certified program-revised procedures and forms and documents for clarity.
• Successfully integrated vision inspection systems which prevented the loss of a ~$100,000+/year
customer.
• Conducted audits, corrective actions, data analysis, SPC, torque and dimensional testing.
• Developed control plans, PFMEA’s, process flow and PPAP documentation. Led APQP and used Six
Sigma tools to meet internal and customer requirements.
• Fluent with requirements of: IFI, DIN, ANSI, GM, Ford, FCA, Tesla, and Military Specifications.
Sales Engineer (1995-2019)
• Doubled sales over 20 years despite industry restructuring to overseas manufacturing.
• Developed strong relationships with customers to assure inclusion on new opportunities.
• Expert technical resource - instilling confidence to specify company products on blueprints.
• Developed pricing based on understanding of production methods, process capabilities and rates.
• Gained specification approvals from major industrial and vehicle manufacturers.
EDUCATION
Bradley University Peoria, IL
B.S. Degree in Communications, minor in Business
Coursework
Six Sigma: Total Quality Applications | Jan 2020
Currently enrolled in IASSC Certified LSSGB Training – Expected completion in Mar. 2020
INTERESTS AND VOLUNTEERING
Bicycle rider, racer and volunteer youth cycling coach.
Engineered, fabricated and raced streamlined bicycles for record events. Top Speed of 70.89 mph in 2012
Founder of the World Human Powered Speed Challenge in Battle Mountain, Nevada
Boy Scouts of America: Assistant Scoutmaster and Merit Badge Counselor
