Post Job Free

Resume

Sign in

Manager Quality

Location:
Phenix City, AL
Posted:
July 30, 2015

Contact this candidate

Resume:

Earkley D. Frazier

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

New Hope, AL 35760

linkedin.com/pub/earkley-frazier/23/913/922

acq0jd@r.postjobfree.com

Home: 256-***-**** Cell: 256-***-****

SUMMARY

Manufacturing Lead with extensive experience in managing multiple areas of manufacturing, production, engineering, maintenance, logistics and quality working within a very fast-paced quality environment. Hands on project management background including development to implementation. Expertise with Kaizen, Lean Manufacturing, 5S, Continuous Six Sigma Methodology to reduce cost while increasing quality and efficiency. Ability to effectively lead and manage 600 professional and UAW hourly employees consistently exceeding company objectives. Worked within multiple programming structures with the knowledge of customizing programs to complement current operating systems and target plant goals. Specialized understanding of manufacturing processes and core business concepts.

PROFESSIONAL EXPERIENCE

Senior Consultant - EDF Consultant Group January 2011– Present

Consultant

Work with Companies that need help with Crisis Management, Line Transfers and reconfigurations, Continuous Improvement, Lean Manufacturing, Six Sigma, Root Cause Analysis, SAP, Customer Satisfaction, TPM, Negotiation, OEE, Data Collection, Operations Management, SPC, Problem Solving, Process Improvement, TS16949, Budgeting, Team Building, Value Stream Mapping, APQP, Quality Systems, Kanban, QS9000, Kaizen, Strategic Planning, Supplier Quality, Cost, Engineering Management, Change Management, Logistics, FMEA. Expert in SQDCM (Safety, Quality, Delivery, Cost, Moral), customizing a program to complement current operating systems and target plant goals.

CONTINENTAL AG / SIEMENS VDO / DAIMLERCHRYSLER, Huntsville, AL 2007 – 2010

Manufacturing Manager / Local Project Lead 2008 – 2010

Accountable for all power train products, engine and transmission systems, and Original Equipment Service (OES) producing in excess of $400M in annual sales, with a budget of $60M. Led and coached a supervisory staff of 12 and 160 hourly UAW employees.

Maintained zero PPM for 17 months and single digit PPM for all products. Successfully developed and lead multiple teams to exceed world class quality and production goals.

Spearheaded a low cost automation workshop that used lean tools that eliminated waste and transition to a cellular manufacturing concept. Increased productivity by 35% reduced work in process by 89% and improved floor space utilization by 67%.

Trained and implemented 5S across the entire business unit for 300 employees and created a 5s audit process that resulted in a 77% increase in 5S scorecard achievement across 15 production lines.

Implemented Kaizen Suggestion System and the use of visual management which increased employee suggestions by 120% and reduced average implementation time from 119 days to 12.3 days.

Implemented Hourly Count Boards, Standard Work Action Item Boards, and Core Teams which improved team work and accountability.

Reconfigured 3 SMD lines (2 Chrysler and 1 Borg-Warner) into U-shaped cells which improved productivity by an average of 53%.

Improved quality standards for 4 consecutive years in Power Train Engine System which dropped from 600 PPM to 12 PPM. Transmissions decreased from 86 PPM to 2 PPM.

SIEMENS VDO / DAIMLERCHRYSLER, Huntsville, AL 2003 – 2007

Manufacturing Manager / Maintenance Manager / Local Project Lead

Project Lead for the build-out of current production on Chrysler lines single board engine controller, electronic transaxle and Jeep’s truck engine controller. Managed the 3rd shift Preventative Maintenance (PM) program and daily manufacturing support. Led 7 supervisors and a skilled team of 60 and a production work force of 120. Directed and implemented a project for machine performance, collected data and charted the results. Analyzed the data and made changes to the frequency of the Preventative Maintenance (PM) and established priority. Improved machine up time, increased production, on-time schedule attainment, 1st time capability and quality enhancements, and reduced scrap.

Selected as project lead for Chrysler New Generation Controller (NGC) line to correct throughput issues. Collected and analyzed data and prioritized to correct all issues which resulted in a complete turn-around in less than 3 weeks.

Also responsible for 2nd and 3rd shift operations including and machine shop and all Preventative Maintenance.

CHRYSLER CORPORATION, ELECTRONICS DIVISION, Huntsville, AL 1987 – 2002

Manufacturing Area Manager

Project Lead on New Generation Controller (NGC) and met target within 2 weeks improving output requirements avoiding retooling and saving $28M in tooling and $3M in overtime and expediting costs. Directed the Electronic Transaxle line and improved quality. Coordinated, scheduled, and tracked training of the 87 Troubleshooters and Wave Solder attendants. Drove the central function approach ensured common implementation of standard operating procedures,

sharing of best practices and lessons learned. Directed 2nd shift operations of engine controller line. Managed 4 supervisors, 149 hourly employees, and a production schedule of 10K units daily with several configurations. Subject Matter Expert for tooling change to reduce no trouble found units at pre-post test from 2.6K daily to fewer than 15.

Exceeded schedule attainment (which averaged 76% for a 7-day workweek) and went to a 5-day workweek at 98%.

Improved parts per million on the New Generation Controller (NGC) by 63% while improving department quality which was the best in Huntsville under a scoring system based on 1st time capability, schedule attainment, scrap and morale. Reduced head count by 44% saving $2.2M.

Selected by management to transfer to the General Motors Transmission line. Improved quality and throughput issues. Improved schedule attainment (was below 60%) to 108% while creating best practices for quality.

Led the Jeep Truck Engine Controller department and ranked the top unit for 9 out of 12 months based upon morale, safety, quality, delivery and cost.

Participated and launched the QS-9000 certification for the entire plant. Created and maintained the MOOP01505 troubleshooter and rework analysis, MOOP01408 control of production line scrap, and MOOP01303 control of non-conforming product assemblies meeting a successful certification.

Assisted in the layout and evaluation of equipment purchased for the Jeep Truck Engine Controller product line – 1 of the company’s most successful product launches in terms of quality and productivity.

Managed the Original Equipment Service (OES) and received 1st Time Capability Award for best in operations.

Selected, led and implemented a large-scale project for the final layout used to produce OES service engine controllers for Mopar, and current low-volume production (ran service with a low volume of 2.3K units daily and a high mix of 2.6K different end items). Finished project with limited and incomplete documentation improving quality with no downtime.

Ran pilot parts for other product lines on the service line, and implemented a corrective action plan to eliminate failures affecting service and plant operations – this led to significant reductions in repair and scrap.

Led key project for the 1st tester correlation between final, pre-pot, and board level test which reduced rework backlogs from a total of 360K units to less than 68 units. Tester correlation strategy was eventually implemented across all product lines in Huntsville. Reduced failure rates by 70% to 95%, cost savings was $350 of millions dollars plus.

CHRYSLER CORPORATION, ELECTRONICS DIVISION, Huntsville, AL 1984 – 1986

Manufacturing Supervisor

Responsible for providing strong leadership to the operational environment to accomplish all group goals and objectives and to maximize productivity while minimizing cost. Help to enhance team effectiveness through improvement actions which directly affect the areas of Safety, Quality, Delivery, and Cost & Morale and facilitate equipment/tooling / process improvement designed to improve individual, team, and line efficiency / performance. Working for continuous improvement activities associated with the shop floor. Work with the Production staff to insure all production operators and skilled trades’ personnel are trained in the operation of all processes and machines (including knowledge of the process) for all associated products, Troubleshooting production floor problems / issues, staffing lines based on output and quality. Continuous Improvement, Lean Manufacturing, Root Cause, Kaizen, Kanban, & Six Sigma skills.

Ability to lead effectively with workers in a union represented setting. Focus on achieving balance scorecard targets in safety, quality, delivery, cost and morale. Oral and written reporting of daily goal attainment and other performance metrics. Collaborative interface with central support groups such as logistics, quality, product engineering, facilities engineering, and human resources. Demonstrate effective oral and written communication skills.

CHRYSLER CORPORATION, ELECTRONICS DIVISION, Huntsville, AL July 19, 1983 - December 1983

Manufacturing Operator

Responsible for setting up and running placement equipment. To make sure we meet or exceed our customer’s requirements.

EDUCATION

High School Diploma – A. P. Brewer Area Vocational and High School, Route 2 Somerville, Al 35670

Vocational Certification – Auto Body and Frame Repair– A. P. Brewer Area Vocational and High School, Route 2 Somerville, Al 35670

CERTIFICATIONS

Supervisor Leadership Development Training, Shelton State Community College, AL, 2010

Six Sigma Green Belt Certification (Siemens VDO), Huntsville, AL, 2007

Six Sigma Green Belt Certification (Advanced Integrated Technologies Group), Huntsville, AL, 2006

AQS-Certified Management System, Inc. ISO / TS 16949 Core Tools Training, Huntsville, AL, 2005

AQS-Certified Management System, Inc. ISO / TS ISO 14001 Introduction, Huntsville, AL, 2005

TS16949 and ISO 14001 Integrated Internal Auditors Training Certification, Huntsville, AL, 2003

Microsoft Certification, Huntsville, AL, 1998

Managing With Statistical Methods Certification, Huntsville, AL, 1997

Problem Solving / Route Cause Analysis Certification, Huntsville, AL, 1995

Affiliations and Awards

Exemplary Leadership and Dedication

Biltmore Who's Who

2008 Fall Open House Vehicle Show

Circuit Court of Madison Country (Grand Jury Duty)

2007 Fall Open House Vehicle Show

Circuit Court of Madison Country (Jury Duty)

Achieving QS-9000 Registration

Outstanding Performance – Engine Control Service Line

Linked-In

Buck Master Life Time Member

North American Hunting Club Life Time Member

Project Management Institute of North Alabama Chapter

Harley Davison HOG Member

United Way



Contact this candidate