Robert D. Cass

Milwaukee, WI

414-***-****

acqzbj@r.postjobfree.com

EXPERIENCE

Rockwell Automation, Inc.

Manger – Quality Assurance (Mequon Operations) (Mequon, WI – 01/12 to Current)

Manager for Operation’s Quality Department (Low Voltage Drives and Printed Circuit Board Assembly Shops)

Exceeded FY13 stretch QA goals (RTYL = -20.2%, IRR = -49.4%)

Exceeded FY14 & FY12 QA goals (RTYL = - 14.2%, IRR = - 22.3% & RTYL = -10.1%, IRR = – 21.7%)

Created, developed and implemented RA Global PCBA MSA process (RTYL (19 months) = -29.2%, 233k units)

Utilized Six Sigma tools, PPAP methodology and historical lesson’s learned to focus DFM&A on New Product Introductions (PF750, Multidrive, High Performance PCBA, Kinetix 5700 - i.e. Gage R&R, QA Plans, Special Characteristics, Process Capabilities, RTYL Acceptance, Control Plans, etc.)

Caterpillar, Inc. (Bucyrus International, Inc.)

Manger – Quality Assurance / Quality Engineer (Milwaukee, WI - 3/09 to 01/12)

Manager for Quality Department (Machine and Assembly Shops) - 28 Team Members (11 Salary + 17 USW)

2010 NCR ticket reduction -32%, reduced Use-As-Is tickets -49% and reduced Scrap / Rework costs -24%

Championed DFM and CAR Teams resulting in NCR reductions and cost savings (Hard $$$ Savings +$590K)

Johnson Controls, Inc.

Lead Program Manager (Chrysler Journey Seats) (Plymouth, MI - 1/08 to 12/08)

Responsible for seat systems consisting of structures, mechanisms, plastic, foam, trim, wires, restraints, etc.

Managed suppliers from business award to PPAP approval of various manufacturing processes such as injection molding, stamping, welding, casting, sewing, multifaceted assemblies, etc. (500+ components, 50+ suppliers)

Accountable for profitability of awarded business with annual sales in excess of $228M

Led team though quote and timing activities for the Chrysler Journey 2010, 2011, and 2012 seat programs

Leadership Development Program – Program Manager (Plymouth, MI - 2/07 to 1/08)

Launched 2008 Chrysler Journey Seat program (Leadership recognition for perfect launch scorecard)

100% on-time seat deliveries for five sequential build events

Created MS Excel Part Matrix to automatically interface with Engineering BOM Matrix, Purchasing PO Matrix, PPAP Matrix, Supplier Readiness Matrix, and PPAP Glide Path

“Elite Support” to prepare and lead supplier’s plant through their first Safety Sign-off (expedited timing 7 days)

Leadership Development Program – Pre-Production Launch Supervisor (Plymouth, MI - 10/05 to 2/07)

Responsible for part matrix, financial tracking, part inventory and procurement systems (EPIC, APX, MFG Pro, BEAM, and SAP) for Toyota 470L pre-production build event (40 vehicle sets)

“Elite Support” to rectify procurement issues for Ford’s Expedition seat launch at JIT Plant

“Elite Support” to procure, assemble, and deliver Core Rear Structure to Chrysler in 3 weeks (100% new design)

Leadership Development Program – Seat Validation Engineer (Plymouth, MI - 2/05 to 10/05)

Managed, coordinated, scheduled, and documented validation testing (federal safety, durability, trim, structural, electrical, etc.) for Ford’s LS and Expedition / Navigator (2nd row) seating programs (600+ tests)

Created, developed and led team to implement reuse plan on 2nd row seats for cost avoidance ($62.4K)

Lead Advance Quality Engineer / Supervisor (Plymouth, MI - 4/02 to 2/05)

Manager of the Advance Quality Team for Nissan’s X61B Seat Programs (4 Senior Advance Quality Engineers)

Responsible for QA deliverables on the four X61B Seat Programs (102 seat PPAPs, 749 component PPAPs)

Launched 2005 Nissan X61B Seat programs (Leadership recognition for X-terra’s perfect launch scorecard)

“Elite Support” to lead team in JIT Plant (Barcelona, Spain) for delivering first X61B prototype seats to Nissan

Senior Quality Engineer / Supervisor (Port Street Seating Plant) (Plymouth, MI - 4/00 to 4/02)

Manager of the Quality Team for Ford’s LS Seat Program at JIT facility (7 salary personnel)

Championed Black Belt Supplier Material Rejection project (annual savings of $237K+)

Key member for 1 shift removal project (20% manning reduction, annual savings of $503K+)

Launched 2003 Ford LS and Feature Car Seat programs (Leadership recognition for perfect launch scorecards)

2002 and 2001 QA Olympics = Gold Rating (Customer PPM < 10 and Internal PPM >70% improvement)

2000 QA Olympics = Silver Rating (50% improvement for customer, internal, and supplier PPM levels, zero customer launch issues; 1999 rating below award criteria)

2000 Achieved JD Powers Best in Class for Initial Quality for Near Luxury Seating (1999 rated worst in class)

Behr America

Quality Systems Engineer (Walled Lake, MI - 1/99 to 4/00)

Responsible for Quality Department’s budget and start-up hiring (Year End = 12% under budget)

Responsible for prototype shop, quality department, CMM, and production line quality equipment procurement

Created, developed, and implemented Supplier Handbook and APQP / PPAP tracking matrix

Supplier Quality Engineer for production supplier selection, APQP, and PPAP (40 parts, 15 production suppliers)

Project coordinator of prototype parts for General Motor’s beta and prototype build events:

Components - 20 suppliers, 40+ component PNs, 65+ Supplier GP11 submissions

Assemblies - 15 assemblies PNs, 35+ Customer GP11submissions

General Electric

Technical Leadership Program - Quality Engineer / Black Belt (Fort Wayne, IN - 8/98 to 1/99)

Led Six Sigma Black Belt projects contributing to $70K annual savings through floor layout and equipment changes (utilized team building, process mapping, CE and FMEA matrices, gage R&R’s, capability studies, ANOVA analysis, Design of Experiments)

Led implementation and start-up of new final test machine ($200K)

Completed General Electric’s Six Sigma Black Belt training

Technical Leadership Program – Sourcing / Purchasing Engineer (Fort Wayne, IN - 1/98 to 8/98)

Responsible for Hardware, Spring, and Integrated Supplier commodity (29 plants, 120 suppliers, 5000+ part numbers, $15 million annual buy)

Developed and implemented price reduction projects equating to $200K (FY98) and 5 year savings of $500K+

AWARDS AND ACHEIVEMENTS

Nominated for Johnson Controls Global Chairman Award (2003 Ford LS Feature Car launch)

Recipient of Johnson Controls Global Merit Award (2008 JC49 Seating Program launch)

Completed Johnson Controls Leadership Development Program (3 year commitment)

Completed Kepner-Trego Project Management Course

Completed General Electric’s Six Sigma Black Belt Training

Completed General Electric’s Leadership Training, Purchasing Development Course, MSU / GE Co-op Program

Founding member of Michigan State Club Hockey team

COMPUTER SKILLS, INTERESTS AND HOBBIES

MS Excel, Word, PowerPoint, Project, Visio, Lotus Notes, Mini-tab, and SAP

Home improvement projects, archery hunting, upland bird hunting, hockey, and fishing

EDUCATION

Lawrence Technological University

Southfield, MI

Pursuing Master’s in Business Administration

(Expected Graduation - Sept-2015)

Current GPA: 3.8 / 4.0

Michigan State University

East Lansing, MI

Bachelors of Science in Mechanical Engineering

Graduating GPA: 3.0 / 4.0

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