JAMES B. O’DONNELL

**** ******* **** • Huntsville, AL 35803

HP 256-***-**** • Mobile 419-***-****

acd7i1@r.postjobfree.com

www.linkedin.com/in/qualitymangement/

QUALITY MANAGEMENT

Quality Assurance • Team Leadership • Process Reengineering

Results-driven and dedicated with wide-range experience planning and leading quality functions

involving small, medium and large manufacturing environments. “I will go the extra mile”.

• Total Quality Management • Six Sigma (Lean Manufacturing) • ISO/TS16949: 2009

• Supplier Quality Management • Advanced Planning Quality Planning • Continuous Improvement

• Statistical Process Control • GD&T Knowledge

PROFESSIONAL EXPERIENCE

Quality Manager

MAI Manufacturing

2006– 2013 Madison, AL & Richwood, OH (6 years 11 months)

Responsible for the Quality Management System for a Tier II automotive supplier.

• Merged the Quality Management System with the Business Management System. (Policies,

practices, procedures and processes).

• Implemented 5S Model. (20 keys to Workplace improvement)

• Responsible for generating new strategies and plans for improving the quality of the products.

• Successful certification to both ISO9001:2008 and ISO/TS16949: 2009 Standards.

• Introduced Supplier Quality Control Program.

• Designed and implemented coaching and training programs to develop staff to facilitate the

efficiency and profitably of the operation.

• Managed operational, capital expense budgets and the quality system.

• Ensured adherence to federal and state regulatory requirements. (OSHA, Department of Labor)

• Implemented Just-in-Time production methodology to control and inventory, resulting in 10%

improvement efficiency.

• Reduced scrap cost by 25%.

• Initiated and facilitated Process Audit Teams for both the Alabama Business Unit and the Ohio

Business Unit. Teams analyzed problem areas, recommended and executed corrective actions

resulting in the reduction of errors by approximately 25%.

• Established a 2nd business location in Madison Alabama.

• Processes included compression molding thermal and acoustical composite products for

American General (military contract), Navistar, Freightliner, Volvo and a number of non-

automotive customers.

Note: Plant closed September 2013 resulting in layoff status.

Quality Manager

Futaba Indiana of America (FIA)

2001 – 2006 Vincennes, IN (5 years 10 months)

Responsible for establishing and maintaining the Quality Management System for a Japanese "startup"

plant located in SW Indiana.

• Greenfield Start-up operation, sales grew from $0 in 2001 to $171,000,000.

• Supervised staff of 4 Quality Engineers, 4 Quality Technicians and 10 inspectors.

• Instrumental in developing US Leadership team in the understanding of Japanese business

practices and proper business etiquette.

• Reduced space required for in-house inventory by 45% through process changes and inventory

and materials control changes. (JIT)

• Trained quality staff in welding processes and weld inspection (Destructive and NDE Methods)

• Successful introduction to Toyota Production System (TPS) and Lean Manufacturing principles.

• Principle lead in the successful implementation and certification to ISO 14001.

• Two major expansions to the plant, including the addition of Stamping Department.

• Processes included, Stamping, Welding (MIG, Spot Weld and Laser Weld) and Assembly. (Body

Structures for Toyota)

Quality Manager

Tower Automotive – Ohio Business Unit (Bluffton OH & Upper Sandusky OH)

1994 – 2001 Bluffton, OH (6 years 5 months)

Planned, trained and executed a continuous improvement program.

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Guided the plant to successful transition from ISO 9001 to TS16949: 1999.

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Introduced Supplier Quality Control Program.

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Responsible for the redesign and upgrade of the Quality Lab. Introduced PCDIMIS software for

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CMM to support GD&T dimensional requirements.

Heavy Metal Stamping, Welding and Assembly (Suspension Components for Ford, GM,

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Chrysler & Toyota)

Senior Quality Engineer

Navistar International

1989 – 1994 Springfield, OH (5 years 4 months)

Designed and implemented ISO 9001 principles and standards for each department; developed

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goals and trained personnel in document control and audit procedures. (2 locations)

Supervised staff of 4 Quality Engineers, 1 Metallurgist, 4 Quality Technicians and 20 inspectors.

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Introduced Supplier Quality Control Program.

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Implemented ISO9001 Standards into the Quality Management System.

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Black Belt Champion, instructed and mentored Black Belt Candidates.

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Key player in the introduction and implementation of a QDC (Quick Die Change) Program

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Played integral role in the introduction of a MRP System.

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Heavy Metal Stamping, Welding, Machining, Assembly and Wire Harness Assembly

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(Automotive – Heavy Truck Industry)

EDUCATION

Sinclair Community College • Dayton OH • Courses in Quality Engineering

University of Tennessee, College of Business Administration • Lean Manufacturing

Harvard Extension School • China: Traditions and Transformations (current)

PROFESSIONAL DEVELOPMENT

Safety: Human Resource Management, Principles/Concepts Occupational Health

Safety: OSHA, Power Press Safety Standards

Quality: ISO/TS16949:2009 Lead Assessor Training

Problem Solving: AT&T Process Mapping, Value Stream Mapping Process

Problem Solving: Systems Thinking Business Process Redesign Methodology (Diffley Associates)

Problem Solving: Ford Global 8D Facilitation Instructor

Leadership: Numerous Leadership seminars, lectures and courses (U. S. Navy)

Leadership: The Seven Habits of Highly Effective People (Covey Leadership Center)

MRPII: Oliver Wight, Principles of MRPII

Lean Manufacturing: Lean Enterprise Systems Design Institute,

University of Tennessee, College of Business Administration

Black Belt – Six Sigma: Black Belt Champion (Trainer for Black Belt candidates)

Computer Literate: Windows 8, Microsoft Office 2013 (Word, Excel, Power Point & Project)

Military Service - U.S. Navy, 20 year veteran (Senior Enlisted - Chief Petty Officer)

Financial – Volunteer Treasurer for local non-profit organization

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