Thomas K. Barry

**** **** ********** **** *****

West Bloomfield, MI. 48324

248-***-**** Mobile

achact@r.postjobfree.com

OBJECTIVES

To integrate my manufacturing leadership skills and knowledge to facilitate

manufacturing quality activities to resolve supplier, design, production

and customer issues. Seek opportunity to supervise teams, develop suppliers

and production support for the resolution of quality process related

issues.

PROFESSIONAL SUMMARY

. Extensive background is in the APQP approvals and developing processes

for program launch PPAP submissions.

. Championed numerous cost improvements exceeding 8.4 million dollars in

cost savings to OEM's.

. Expert in documentation skills in process flow mapping diagrams,

control plans, PFMEAs, RPN reduction plans, gauge plans, gauging,

error/mistake proofing, work instructions, handling of nonconforming

material, and quality related process improvements.

. Performed on-site technical and quality system supplier

audits/assessments of suppliers'

. Successfully fostered and achieved plants QS/ISO 16949 / AS9100

certifications while at Sodecia, Dana, Franklin Fastener, Kelsey-

Hayes, Sanyo, Fujitsu and Chrysler.

. Lead teams to ensure proper containment, root cause analysis, and

corrective action implementation and verification.

. Performed run @ rates, tool moves and capacity reviews, for launch

readiness reviews at various plant / supplier locations.

. Facilitated meetings with internal/external customers, suppliers,

regarding process control, and measuring the effectiveness.

. Served as liaison Ito developed both suppliers and customers on

continuous improvement initiatives.

. Resolved numerous process issues on purchased components in areas such

as improved control plans, PFMEAs, RPN reduction plans, gauge plans,

gauging, error/mistake proofing, work instructions, handling of

nonconforming material, and quality containment activities.

. Directed on-site technical and quality system audits/assessments with

Magna, TRW, Ford Motor, and Chrysler.

CAREER EXPERIENCE

Martinrea - FABCO Detroit Plant

06/07/2013 - Present

Sr. Quality Engineer

Accomplishments: Vastly improved root cause analysis and corrective actions

on complex systemic hot stampings, and welding fabrication process issues.

Facilitated and improved customer expectations resolving plants chronic

process deficiencies. Lead instructor to trained team in new quality

techniques, principles and best practices. Significantly reduced plant

PPM's and assured plan compliance to TS16949 / ISO 14000 certification

requirements. Created new benchmarks and planned approached to assured all

required quality systems and process performance goals achieved. Create

PPAP submissions for customers. Promote teamwork and corrective actions

with suppliers and OEM customers. Assure effective compliance with the APQP

process and approve supplier / customer PPAP submissions.

Barry Technical Management Consultant (Contract Assignments)

07/09/2001 - 02/08/2013

President / CEO

Consultant clients include: Sodecia - Sterling Heights Plant, Hollingsworth

Logistics Group, Franklin Fastener, Ford Motor Company, Dana, Chrysler-

MOPAR, JCI, Lear Corporation, Fujitsu Ten Corporation, Sanyo, & Moller-

Tech. Served as Quality Manager, STA, Program Quality Manager, Reliability

Engineer & Quality Director

Accomplishments: Develop manufacturing in tooling stamping, and welding

processes. Facilitated process control of manufacturing concepts, root

cause analysis, techniques, principles and practices. Assured plan

compliance to TS16949 / ISO 14000 certifications.

Assured all required quality systems and process performance goals are

maintained. Evaluate performance of quality department personnel establish

department priorities of staff and other departments within plant. Promote

teamwork and corrective actions communicated to suppliers and OEM

customers. Assure effective compliance with the APQP process and approve

all supplier / customer PPAP submissions. Obtain ISO 9001:2000

registrations, Maintain ISO 9001:2000 registrations, Prepare responses for

any non-conformance's issued by the customer, Trained staff related to

quality issues, Made recommendations to management regarding the quality

improvement process, Managed department employees, Facilitated program

launch quality meetings. Worked with OEM customers suppliers resolving

critical quality issues. Maintained statistical data base demonstrating

quality systems. Develop gauge and measuring device calibration strategy,

Developed standards and assure maintenance and calibration of all gages and

measuring devices. Obtained all necessary quality certifications and lab

results, Monitor key processes, provided direction for obtaining brokerage

services for importing and exporting. Developed and maintained the quality

systems, TS16949 & AS9100 certifications, coordinated PPAP and vender

issues as related to the manufacturing of metal components that are

supplied globally and the production plans necessary to support them. Work

directly with Production, Engineering and Purchasing to developing workable

plans that maximize customer service levels and minimize total cost of

quality. Facilitated manufacturing sites for Ford suppliers to gain

successful obtain Q1/ ISO/TS certifications. Assured the optimal amount and

type of information is readily available to all manufacturing team members

on a timely basis to allow the teams to accomplish optimal performance

levels and procedure changes. Lead manufacturing teams with the use of

problem solving techniques, process improvement techniques, Partnered with

customer personnel to achieve optimal performance levels and resource

allocations. Coach, mentor and support quality clients personnel to ensure

certification and compliance with ISO/TS-16949 requirements. Obtain and

resolve critical engineering drawings, part releases, tooling, purchasing

distresses suppliers and process issues with critical Ford suppliers.

Provide assistance and direction to achieve optimum of cost, quality and

delivery targets.

Barry Technical Management Consultant (Contract Assignments)

Ensure systems and processes are effective in producing and delivering

parts that meet service quality, cost and schedule requirements.

Responsible for the development, management activities, and priorities of a

service part suppliers. Develop teams that will improve supplier processes

to support critical service parts. Drive improvement in plant quality

performance warranty, customer PPM's, internal PPM's, scrap, etc. Ensure

the quality team is fully qualified and consistently exceeding

expectations. Plan aggressive plant quality objectives and drive the action

plans to achieve those objectives. Ensure corrective action processes are

comprehensive, fast and effective. Ensure all new and changed products are

fully validated for compliance and capability prior to implementation, and

proper approvals Monitor supplier quality and hold suppliers accountable

for product which is not compliant and work with supplier development on

consistently problematic suppliers. Communicate performance and critical

issues appropriately through the organization, customers and suppliers.

Manage quality process within the plant requiring involvement with staff

decisions that affect the operation of the plant. Developed project plans,

work breakdowns structures, and establish product schedules and resolve

timing issues on re-core salvage component parts. Facilitate the direction

and assistance to re-man unique suppliers in order to achieve compliance to

ISO/QS9001 system requirements. Identify process improvements and develop

cost reductions proposals for engines and transmissions. Interface with

Program Engineering, Supplier Technical Assistance, Manufacturing,

Purchasing and Quality to implement optimum Six Sigma process improvements.

Provide direction on the development and approval of MOPAR re manufacturing

suppliers and coordination of process improvements and engineering changes.

Review, develop, verify, sign -off on supplier's PPAP PSW and PSO strategy

for production of MOPAR service parts. Approve and verify control

documentation, D/PFMEA, DVP&R, and Manufacturing Process Flows, Control

Plans, Work Instructions, Process Improvements, Tooling Equipment, Gages,

Process Monitoring and Planning, Warranty and 7 Step problem solving

corrective actions methods on service parts. Established set up of new

production process improvement plans. Develop the advancement of PPAP

quality practices to obtain approvals on APQP activity and PPAP submissions

for plant. Responsible for management of all GM APQP & PDT launch

activities for GM250 audio program. Create BOM, DFMEA's, R&R, Flow Charts,

Pre-launch Control Plans, DVP&R testing for PPAP submissions and PDT

meetings. Coordinate Program Management and supervise activities to ensure

products meet customer expectations and MS Project quality objectives.

Represent corporation to resolve design and manufacturing issues. Provide

on- site direction for successful program launch implementation. Support

procedural execution of initiatives to increase productivity, reduce scrap

cost, and enhance process quality. Represent corporation to resolve quality

design and manufacturing issues. Pursue root-cause, corrective actions, and

continuous improvement activities with OEM customers.

Lear Corporation - GM Warren Division

10/14/2000 - 5/28/2001

Senior Corporate Program Quality Engineer

Accomplishments: Evaluated the PPAP packages of external suppliers to

confirm the documentation is accurate and meets expectations.

Coordinate Run @ Rate and DVP&R testing and product validation to GM

specifications.

Johnson Controls, Inc.

07/19/1999 - 9/10/2000

Senior Program Launch Quality Engineer

Accomplishments: Support APQP meetings and coordinate quality activities

for electronic instrument panel during launch of vehicle.

Develop and maintain PPAP activities, control plans, flow charts, and

D/PFMEA's. Contribute corrective actions root cause analysis to design

issues.

Kelsey-Hayes - Lucas Varity - (aka TRW)

05/12/1992 - 4/16/1999

Plant Quality Manager / Senior Quality Engineer / Senior Engineering

Quality Liaison

Accomplishments: Supervise and support staff in quality production

activities championing opportunities for improvement of ASB brake

components in the plant. Serve as lead auditor to facilitate the

maintenance of QS9000 requirements for the plant. Made process

Improvements reducing customer PPM's and resolution of process issues and

corrective actions.

Other OEM Relevant Experience:

General Motors Corporation - CPC - Senior Product Quality Assurance

Administrator - 8 years

Ford Motor Company - NAAO Expeditor / Auditor / Buyer - 6 years

LTV Aerospace and Defense - HUMMVI - RAM-D Reliability Engineer - 1 year

EDUCATIONAL BACKGROUND

Eastern Michigan University, B.S. / Industrial Technology - Quality

Management

Central Michigan University, Masters in Business Administration -

Management and Supervision

Certified ISO Auditor / Lead Assessor - RAB

Six Sigma Green Belt

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