Injection Molding Consultant Erik Hoenes
Injection Molding Expert Erik Hoenes
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Erik is an innovative plastic product design and manufacturing engineering leader with 25 years of experience spanning from conceptual design and prototyping to high-volume mass production. He has strong polymers, tooling, assembly, metrology, and automation knowledge encompassing various manufacturing processes including utilization of high-speed automation systems. Erik has proven results utilizing business acumen and technical expertise to improve organizations, drive large-scale cost reduction, and achieve excellence in new product launches.
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STRATEGIC VISION
Strong business acumen leveraging technical knowledge and strategic planning to achieve aggressive performance and financial results. Passionate about details while maintaining continual focus on the big picture.
PLASTIC PRODUCT DESIGN, TOOLING, PROCESSES, & AUTOMATION
Skilled design & process development expertise for low to high unit volumes, from prototyping to automated mass production. Broad knowledge of plastics manufacturing processes and established relationships with tooling, molding, forming, and automation suppliers
DESIGN FOR MANUFACTURING
Over 25 years of experience refining new product designs and manufacturing introduction plans utilizing DFx skills, Lean manufacturing concepts, Solidworks, FEA, and Moldflow analysis
VALUE ENGINEERING
Demonstrated experience with features vs. cost analysis and product/system design optimization for cost/quality/delivery performance resulting in double digit millions in cumulative savings
PROGRAM MANAGEMENT
15+ years of experience managing staff in cross-functional matrix environments. Successful track record of driving staff performance for on time project delivery via DBS and other project management tools, including visual project management, action plans, Gantt charts, payoff matrices, daily management tactics, and MS Project
PROTOTYPING / ADDITIVE MANUFACTURING / 3D PRINTING
Knowledge of DFM, materials, processes, and suppliers for CNC machining, casting, rapid tooling, and additive manufacturing
MEDICAL DEVICE DESIGN CONTROLS & REGULATION
15+ years of experience guiding staff under FDA Class II medical device design controls, including IQ/OQ/PQ protocols
Experience
October 2019 – Feb 2021
Aktiv Pharma Group
Director, Manufacturing Engineering
Colorado, USA
Head of Manufacturing Engineering organization tasked with leading development of manufacturing solutions supporting the launch of novel drug delivery device platforms utilizing polymer primary drug containers
January 2018 – September 2019
Beckman Coulter Diagnostics
Senior Manager, Global Plastics Engineering
California, USA
Head of Global Plastics Engineering organization supporting New Product Development, Value Engineering, and Manufacturing Operations for biomedical diagnostic instrument & consumable products
June 2015 – December 2017
Beckman Coulter Diagnostics
Senior Manager, Mechanical Engineering (Plastics, Tooling, & Automation)
Leader of corporate engineering team tasked with supporting global New Product Development, Value Engineering, and CA Manufacturing Operations for biomedical diagnostic instrument & consumable products
June 2008 – June 2015
Beckman Coulter Diagnostics
Senior Staff Mechanical Engineer, Plastics Lead, Value Engineering
Dual-role entrepreneurial leader of start-up corporate Value Engineering plastics team, managing several engineers in addition to performing individual project duties focused on optimizing product design, tooling, & manufacturing processes for cost reduction and quality improvement resulting in double digit millions of cumulative savings within seven years
October 2003 - May 2008
Beckman Coulter, Inc.
Staff Engineer, IVD Products Engineering Supervisor, Plastics
Engineering lead and manager of several engineers supporting clinical chemistry and hematology diagnostics products focused on injection molding and assembly of IVD medical instrument components and consumables
July 2000 - October 2003
Apple Inc.
Process Engineer, Product Design; Tooling & Process Engineering
Cupertino, CA
Supported plastic and elastomeric part design, tool builds, process development, engineering changes, and raw material selection while managing information flow between international suppliers and Apple staff in Cupertino
May 1996 - June 2000
Corning Optical Communications, LLC
Mold Flow Engineer, Process & Tooling Engineering (1997 – 2000)
Manufacturing Engineer, Injection Molding (1996 - 1997)
Keller, TX
Improved new product designs and manufacturing processes, designed & procured injection molds, managed department intern, and led capital equipment projects for components used in fiber optic connector & copper protection/enclosure applications
Education
Texas A&M University, College Station, TX, Bachelor of Science in Mechanical Engineering
October 2019 – Feb 2021
Aktiv Pharma Group
Director, Manufacturing Engineering
Colorado, USA
Head of Manufacturing Engineering organization tasked with leading development of manufacturing solutions supporting the launch of novel drug delivery device platforms utilizing polymer primary drug containers
- Ownership of strategy and rapid development of custom drug delivery device manufacturing equipment & process solutions
- Managed staff to mature device assembly, tooling, molding, metrology, & automation systems
- Support of executive management team with long-term manufacturing strategic planning and cost models
- Direct support of product development team with plastic part design, tooling design, materials, and DFM solutions
January 2018 – September 2019
Beckman Coulter Diagnostics
Senior Manager, Global Plastics Engineering
California, USA
Head of Global Plastics Engineering organization supporting New Product Development, Value Engineering, and Manufacturing Operations for biomedical diagnostic instrument & consumable products
- Responsibility for enabling growth and sustainment of product revenues approaching $5B, driven by IVD instrument placements and recurring sales of reagents utilizing plastic injection and blow molded consumables
- Ownership of long-term strategic plan and budget for global plastics engineering activity, including double digit million per year capital spend
- Actively managed staff at multiple sites to optimize part, assembly, tooling, & automation system design, raw material selection, process development, validation, manufacturing support, supplier evaluations, and long-term asset management
- Responsible for cross-functional resource alignments within a large matrix organization
June 2015 – December 2017
Beckman Coulter Diagnostics
Senior Manager, Mechanical Engineering (Plastics, Tooling, & Automation)
Leader of corporate engineering team tasked with supporting global New Product Development, Value Engineering, and CA Manufacturing Operations for biomedical diagnostic instrument & consumable products
- Primary leadership role driving company plastics engineering strategy and technology progression, including responsibility for all California plastics engineering activity and asset management
- Oversaw innovative tooling designs & process improvements resulting in industry first applications of new technology
- Directly managed engineering team in execution of over 40 projects spanning NPD, VAVE, & Manufacturing
June 2008 – June 2015
Beckman Coulter Diagnostics
Senior Staff Mechanical Engineer, Plastics Lead, Value Engineering
Dual-role entrepreneurial leader of start-up corporate Value Engineering plastics team, managing several engineers in addition to performing individual project duties focused on optimizing product design, tooling, & manufacturing processes for cost reduction and quality improvement resulting in double digit millions of cumulative savings within seven years
- Recruited and developed talent for start-up engineering team as first hire and leader of all plastics VAVE activity
- Direct responsibility for team project selection, budgets, schedules, ROI, financial analysis, risk management, and P&L
- Optimized the design of high volume consumables for cost & cycle time savings, receiving design patents
- Developed new breakthrough high cavitation tooling work cells and automation systems
- Directly managed seven staff members and 30 simultaneous projects in addition to internal machine shop workload
October 2003 - May 2008
Beckman Coulter, Inc.
Staff Engineer, IVD Products Engineering Supervisor, Plastics
Engineering lead and manager of several engineers supporting clinical chemistry and hematology diagnostics products focused on injection molding and assembly of IVD medical instrument components and consumables
- Led engineering team in developing tooling, machinery, and processes for manufacturing of new products, sourcing suppliers, and designing injection molds
- Designed replacement hot plate welding & assembly machine for key consumable in cooperation with custom machine builder to improve throughput, reliability, weld quality, tolerances, and provide 100% leak detection of product
- Modified design of clinical chemistry consumable to allow for automated assembly
July 2000 - October 2003
Apple Inc.
Process Engineer, Product Design; Tooling & Process Engineering
Cupertino, CA
Supported plastic and elastomeric part design, tool builds, process development, engineering changes, and raw material selection while managing information flow between international suppliers and Apple staff in Cupertino
- Performed DFM reviews utilizing molding knowledge and Moldflow analysis to improve product designs prior to tooling
- Assisted in tooling design and recommended improvements with emphasis on mold feed & cooling systems
- Worked hands-on with international suppliers to develop injection molding processes for desktop, laptop, mobile device, power, & accessory products designed to stringent cosmetic standards and tight tolerances on a wide variety of machinery
May 1996 - June 2000
Corning Optical Communications, LLC
Mold Flow Engineer, Process & Tooling Engineering (1997 – 2000)
Manufacturing Engineer, Injection Molding (1996 - 1997)
Keller, TX
Improved new product designs and manufacturing processes, designed & procured injection molds, managed department intern, and led capital equipment projects for components used in fiber optic connector & copper protection/enclosure applications
- Designed precision fixturing and SPC measurement systems for fiber optic connector components to very tight tolerances
- Reviewed new product designs and improved manufacturability utilizing CAE analysis tools
- Managed injection molding machine, robot, and auxiliary equipment installation projects
Education
Texas A&M University, College Station, TX, Bachelor of Science in Mechanical Engineering
- Tau Beta Pi National Engineering Honor Society
- Pi Tau Sigma National Mechanical Engineering Honor Society
- Texas A&M University College of Engineering Distinguished Student Award
- Reagent cartridge for holding reagents in a chemistry analyzer
- Optimized IVD Cartridge design to reduce raw material usage by approximately 45,000 lbs./yr. and improve part DFM for molding cycle time reduction while maintaining cold temperature drop test performance. Incorporated refined part geometry in new design of injection mold tooling, doubling cavitation & reducing cycle time by 22%, resulting in hundreds of thousands per year in cost savings.
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