MICHAEL A. ZERNICK
Oregon, WI 53575
acplso@r.postjobfree.com
CAREER SUMMARY
. Developed, managed, and implemented Quality and EHS Systems from the
High Seas to the South Pole and with manufacturing and distribution
sites all over the world.
. Process Improvement Leader.
. Successful Implementation of DuPont and SafeStart Systems, behavior
based Safety Programs.
. Expertise in TS 16949, ISO 9001 and ISO 14001 requirements and
registrations.
. Customer-focused Supply Chain Manager and Problem Solver.
. A hands-on Manager with a record of increasing sales and exceeding
established goals both internally and externally with Customers and
with Suppliers.
. My most important managerial duty is to be the mentor for my people as
well as others within and without the organization. I make others more
successful.
. I have both developed and re-engineered processes to make them more
efficient and error free.
. I consider myself to be the consummate Trainer. I have trained and
implemented all elements of the ISO standards, as well as SPC
techniques and HazMat safety.
. Management and mitigation of risks.
PROFESSIONAL EXPERIENCE
Hamlin Electronics/Littelfuse, Lake Mills, WI.
2013-present
$800 Million High-Speed Reedswitch Assembly
Quality and Continuous Improvement Manager
. Developed, Implemented and managed Quality programs.
CAPA/ Corrective Action
. Response time reduced to: 4D: 5 days/8D: 15 days
Nonconforming Material
. Turnaround Time < 48 hours
Scrap Reduction Program
Streamlined and clarified Reedswitch Visual Inspection
Standards.
. Pushed successful Process Improvement efforts despite transfer of
business from Wisconsin to Asia.
. Managed ISO-14001 (EH&S) Activities
. Managed TS-16949 (Quality Management System) Activities
. Performed Internal TS/ISO audits
. Re-engineered Failure Analysis Process and Process for handling
Returned Material.
. LEAN Principles/Process Mapping
. Supervised and mentored three Quality Engineers and two Test
Engineers.
. Acted as a focal point for communication both internally among other
divisions and externally with Customers.
. Restructured the Quality Department to best serve internal and
external Customers.
. Developed and Implemented Product/Equipment Validation Plans for the
Operations transfer to Asia.
Consortium for Ocean Leadership, Washington DC.
2011-2013
Ocean Observatory Initiative (OOI)
OOI Project: $400 Million Project to construct four oceanic observatories.
OOI Quality and Safety Manager
. Developed, implemented, and managed Quality and Safety Programs at
multiple sites.
. Developed, implemented, audited and managed an Internal and External
Quality Auditing Program.
. Managed Quality and Safety professionals at multiple sites.
. Developed a Non-Conformance reporting System, covering multiple sites.
. Completed permit applications and managed the Environmental Compliance
Permitting Process.
. Provided Quality and Safety Training for the OOI Project.
. Implemented Lean Concepts in process design and re-design.
University of Wisconsin, Madison, WI.
2004 to 2011
IceCube Project: $270 Million Project to construct a neutrino-detecting
telescope at the South Pole.
IceCube Quality and Safety Officer
. Developed a Failure Review Board and Non-Conforming Material Process
where all issues were closed, reducing the failure rate to approximately
%. We anticipated a 10% failure rate.
. Jump-started an organized problem-solving effort.
. Introduced a Peer Safety Auditing Program at the South Pole.
. Created the Incident Reporting Process at the South Pole.
. Directed the Development of Emergency Evacuation procedures.
. Hired and trained a new Quality/Safety Engineer as a back-up at the South
Pole.
. Oversaw the Safety Hazards Analysis Process for all systems at the South
Pole each year.
. Managed the process for the revision of the Job Specific procedures.
. Organized all safety training each year.
NEWARK INONE (formerly Newark Electronics), Chicago, IL
1998 to 2003
$ 500 Million Distributor of Electronic Components/ 1500 employees
Quality Assurance Director
Managed 50 sites/ 20 subordinates. Management Representative for the
Quality/ Business Management System. Developed process re-maps as required.
Trainer in all facets of the ISO standards. Performed all corporate and
plant DOT training.
. Led cultural change in Warehouse by collectively designing and
implementing a Quality Accountability Program.
. Designed and implemented ISO-9001: 2000 conversion At Newark InOne in
four months.
. Directed and implemented the ISO-14001 EMS standard in seven months.
. Enhanced Internal Quality Auditing and Corrective/ Preventative Action
processes, cut CAR cycle time in half (including Supplier CARs).
. Created and implemented consistent processes to address customer
requests, instituted tracking system.
. Developed Six Sigma process performance benchmarks. Instrumental in
developing OTIF (Customer Service Level Metrics). OTIF performance
increased 50% in two years. Enhanced and sustained several key Customer
relationships including LHMC, Hamilton-Sundstrand, and Boeing.
. Established On-Line (Intranet) availability of all Procedures/ Work
Instructions.
. Supplier Relations:
o Worked with Suppliers and Purchasing to resolve Quality problems
through both site visits and Supplier meetings at Newark. Hands-on
involvement with the Supplier Corrective Action process and the
Nonconforming Material processes.
o Partnered with Suppliers and IT Group to provide integrated on-line
MSDS availability.
o Led a cross-functional team, inclusive of our Supplier Base, in
Automation for Manufacturer's Certification storage,
retention, and retrieval processes. Reduced retrieval time for
MFR certifications by 90%.
o Developed and implemented a Supplier Checklist to rate Supplier's
overall performance in order to baseline Suppliers for Improvement.
. Managed a HazMat stock transfer from one site to another.
. Played a key role on Transitional Management Team in closing Chicago
Warehouse. Managed Inventory Control/ Quality function that maintained
99% outgoing quality level through the final shipment as measured through
SWARM.
TOTAL CONTROL PRODUCTS, Melrose Park, IL
1997 to 1998
$ 200 Million PC and Plant Process Controls Manufacturer, Major Automotive
Supplier/ 100 employees
Quality Assurance Manager
Management Representative for ISO-9002 Quality System Registration.
. Supplier Relations:
o Performed on-site Supplier Assessments.
o Worked with Suppliers through site visits to solve problems.
Frequent domestic travel.
o Integrated Supplier Corrective Action data in TCP Corrective Action
process for Process Improvement.
. Developed a consistent Internal Quality Auditing Program.
. Managed UL Audits.
. Enhanced the Incoming, In-Process, and Final Inspection & Testing
Programs. Initiated a process to track production line errors for process
improvement and to reduce scrap and rework.
. Developed Process Control Programs including: a Product Returns Policy,
Lot Control Program, and a Bar-Coding Program.
TRIPP LITE, Chicago, IL
1995 to 1997
$225 Million Consumer Electronics Manufacturer/ 350 employees
Quality Assurance Manager
Management Representative/Project Manager for successful ISO-9002
Registration effort. Supervised and trained two Quality Engineers and
eleven auditing technicians, both locally, in Mexico, and in Asia.
. Designed and implemented ISO-9002 registration at Tripp Lite in seven
months from concept.
. Established Company-wide Corrective and Preventative Action system.
Originated the Internal Audit function.
. Supplier Relations:
o Instituted a 1st-Piece Approval System, on-site with Suppliers in
order to reduce product deficiencies by 50%.
o Frequent International travel to train resident QA Technicians and
to trouble-shoot production problems at Supplier's facility.
o Introduced statistical analysis to quantify Supplier problems for
resolution. Cut number of problems in half.
o Performed Supplier Assessments both domestically and
internationally.
. Commenced product reliability testing using a Life Cycle program in order
to develop product warranty information.
. Proposed, developed, and initiated Statistical Analysis to include
customer complaints, customer returns, and plant product failures,
resulting in fewer customer complaints and increased internal process
efficiencies.
REMCOR PRODUCTS COMPANY, Glendale Heights, IL.
1992 to 1995
$40 Million refrigerated beverage dispenser manufacturer in partnership
with Coca Cola and PepsiCo.
Quality Assurance Manager
Established and maintained quality programs in accordance with corporate
directives and customer needs.
Instituted policies and procedures for ISO-9001 Registration.
P3
. Supplier Relations:
o Ensured Quality and on-time delivery by introducing a Supplier
Rating System with Purchasing in order to track Supplier
performance towards improvement.
o Established a system for Supplier Assessments to assist with
process improvement. Performed these assessments and integrated
these results back into the Corrective Action process for
improvement.
o Frequent visits to Supplier sites for trouble-shooting and problem
resolution.
. Developed Internal Audit program that encompassed on-line product audits,
internal quality metrics and workmanship standards.
. Trained plant production staff in problem solving fundamentals and SPC
techniques.
EDUC
EDUCATION
Bachelor of Science, University of Notre Dame, Notre
Dame, IN.
PROFESSIONAL DEVELOPMENT AND AFFILIATIONS
Certified TS 16949 Auditor.
Judge for the American Society for Quality's
"International Team Excellence Award."
o Companies compete in major Process Improvement or Corrective Action
efforts.
Certified Quality Auditor (CQA), American Society for
Quality. Currently a Member.
Certified SafeStart Instructor.
Behavioral Based Frontline Supervisory Safety Training Certificate from
DuPont.
Six Sigma Green Belt training
Hamilton-Sunstrand
Lockheed Martin
Quality Control Academy
Various seminars in ISO-9001: 2000; Internal Quality Auditing; Corrective &
Preventive Action; Quality Planning.
Rockwell Automation
ISO-14001 Seminar
Internal EMS Auditing (ISO-14001)
"Quality Improvement through Defect Prevention"
Certificate: Phil Crosby Course.
(NAPM) National Association of Purchasing Managers
Presenter for own paper: "Purchasing Inspection on a Shoestring."
View Engineering, Inc., Simi Valley, CA
Programmer's Certificate for CMM operation.
SME (Society of Manufacturing Engineers)
Certificates for Geometric Dimension and Tolerance and Inspection training.
Moderate fluency in the spoken, written, and reading of the German
language.