BILL HAYS

*** **** ****, ******, ** *****, Ph. 803-***-****, e-mail: ab2mcq@r.postjobfree.com

PROFILE

Results oriented professional with experience in Quality, Engineering, R&D, Operations, and General

Management. Proven track record of accomplishments improving quality, reducing cost, and developing

new products through the use of cross functional teams, lean principles, and the application of statistical

design and problem solving techniques.

ACCOMPLISHMENTS

• Quality: Designed and installed quality systems and led organizations to achieve Ford Q-1

certification and ISO 9001/TS-16949. Used DMAIC and team problem solving to reduce quality

defects by 75% and reduce cost by over $800K.

• Operations/Manufacturing: Managed pilot manufacturing and test facility with 32 hourly and 5

professional employees. Utilized kaizen and other lean methods to increase productivity by 70% in

12 months.

• Engineering: Setup and managed technical department for new friction materials company including

creating product development and engineering standards systems. Coordinated advanced research

activities with corporate research labs. Using lean daily management and kaizen techniques, reduced

product cycle time 60% in 3 years as manger of foundation brake design team.

• General Management: Launched small businesses with responsibility for all aspects of the business,

including Profit and Loss, Product Development, Marketing, Purchasing, Operations, Finance and

Human Resources. Senior management team member on Greenfield launch of new production

division for Tenneco Automotive.

EXPERIENCE

LA-Z-BOY, INC., DAYTON, TN 2010-present

Manufacturer of Upholstered Furniture

Quality Director

Led quality function for manufacturing operation with $200+ million in sales, 1400 employees, and 4

manufacturing operations. Quality organization included 7 direct reports and 42 employees total, including 4

managers. Restructured the organization to improve focus on the primary mission of improving customer

satisfaction by creating a culture of quality throughout the organization.

Achievements:

• Reduced Cost of Quality 18% and Cost of Failure 24% in 24 months

• Implemented Toyota Kata Continuous Improvement process campus wide.

• Reduced end of line inspection costs by 20% in 18 months.

• Implemented use of detailed Work Instructions, FMEA and Control Plans.

• Reduced Customer Complaint Rate 70% in 12 months with Voice of the Customer Award System.

• As part of the site Lead Team, won 2012 Industry Week Best Plant in North America Award.

ACOUSTEK NONWOVENS; STATESVILLE, NC 2008 – 2011

Tier 1 Producer of Automotive Interior Insulation Panels.

Quality Manager

Supported this Tier One Automotive Parts Manufacturer Part Time in the role of Quality Manager as a client

of Process Champions.

Achievements:

Supported launches of new products for Chrysler, Ford, Johnson Controls, Rieter Automotive and

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other Tier One automotive suppliers.

Managed Corrective and Preventive Action System and overall Quality System for continued

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certification to ISO/TS16949

Upgraded quality systems in support of lean initiatives reducing administrative non-value added labor

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by approximately 75%.

PROCESS CHAMPIONS LLC; ROCK HILL, SC 2004 – 2011

Quality and Lean Consulting and Training

President

Achievements:

• Provided training in statistical design and team problem solving to Schaeffler Group (Ina Bearings).

• Provided internal audit and ISO tools training to a variety of clients including Freightliner, InChem

Corporation, Champion Labs, ArvinMeritor LLC and Acoustek Nonwovens.

• Provided process support and problem solving to ArvinMeritor LLC and Acoustek Nonwovens,

including 6-Sigma project support.

• Set up and conducted public training course programs in Lean Manufacturing, PPAP, APQP,

Problem Solving and 5-S.

PERFORMANCE FRICTION CORP; CLOVER, SC 2002-2004

Manufacturer of Automotive Brake Pads.

V.P. Quality

Led quality function of privately held multi-national company with locations in South Carolina, North

Carolina, Michigan and the United Kingdom. Responsible for quality, safety and training for the corporation.

Achievements:

• Improved quality systems for TS16949 certification.

• Redesigned APQP process reducing product cycle time 25%

• Reduced third-party non-conformances by 62%.

• Implemented new Supplier Development process (TS16949 compliant).

• Implemented training curriculum for production and professional workers to support use of Quality

Systems and SPC on the shop floor.

ARVINMERITOR LLC; YORK, SC 1991 - 2002

Manufacturer of Off-Highway Axles, Brakes and Brake Components.

Quality Manager 2001 – 2002

Managed a staff of 4 quality engineers and 6 technicians.

Achievements:

• Through application of 8-D and DMAIC methods, reduced Customer PPM from 2000 to 500 in 6

months.

• Led organization to achieve Ford Q-1 certification

• As 6-Sigma Champion trained 2 6-Sigma Black Belt Candidates

Product Manager, Friction Materials 1998 – 2001

Responsible for development of strategic product plans, working with customers to promote the sale of

Meritor friction materials and evaluate the strategic fit of this business in the Meritor product line.

Achievements:

• Developed strategic product plan including potential growth outlook

• Participated on divestment team for this business.

Manager, Brake Engineering 1996-2001

Led current engineering brake design team. Improved current designs for improved reliability and lower

cost. Customized designs to meet customer needs. Managed staff of 4 design engineers and 4 drafters and

administrative personnel.

Achievements:

• Through use of lean daily management and kaizen principles, led team to reduce project cycle time

over 10% per year for 2 consecutive years and 40% reduction in the third year.

Research and Development Manager 1991-1996

Responsible for development of new friction materials for OEM on-highway, off-highway and aircraft

applications, including management of brake test laboratory. Managed staff of one R&D engineer and 2 lab

technicians.

Achievements:

• Developed company’s first on-highway truck brake lining

• Developed patented phenolic piston design for use in off-highway hydraulic brakes

• Coordinated advanced research activities with corporate research labs and university research.

• Co-Author of “The Role of Surface Science in Friction Material Studies”, presented at the SAE

Brake Colloquium, October 1996

• Nominated for Rockwell International Engineer of the Year Award, 1996

• Chairman, Brake Lining Committee of the Society of Automotive Engineers.

EDUCATION

MBA Winthrop University (4.00/4.00), Rock Hill, SC

• Elected to Beta Gamma Sigma Honorary Fraternity

M.S. in Materials Eng (3.75/4.00), RPI, Troy, NY

B.S. in Chem. Eng. (3.18/4.00), Northwestern Univ., Evanston, IL.

PATENTS

Inventor: U.S. Patent 6,499,571: “Brake pad with improved green performance”

Co-Inventor: U.S. Patent 6,405,840: “Rigid panel attachment for brake linings”

Inventor: U.S. Patent #4,748,192 “Friction Material”

OTHER SKILLS AND CERTIFICATIONS

Lean 6S Master Black Belt, ASQ 6S Black Belt, ASQ CQM, ISO/TS16949 Lead Auditor

Hoshin Planning, AIAG Core Tools (APQP), QFD, Theory of Constraints, SMED, Toyota Kata

Familiar With: Composite Mixing, Compression Molding, CNC Machining, Turning, Welding, Painting,

Plating, Stamping, Heat Treating, Assembly, Packaging, Food Handling, Furniture Assembly. Upholstery

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