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Quality Assurance Manager

Location:
Birmingham, AL
Posted:
January 28, 2016

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Resume:

Rick L. Mason

334-***-******* River Birch Circle – Wetumpka Al. 36093

Dear Employer:

I would like to bring my proven skills to your company to work together in producing quality products and services while increasing profitability for your company. My various experiences and education in improving processes would bring value to your company.

I look forward to an Interview with your Company to discuss my opportunities and to contribute my technical skills.

Qualifications & Skill Set

Manager of Technical Support – Manufacturing & Process Engineering – Sheet Metal/Composites – Tool Fabrication/Detail & Major – Tool Engineering - Quality Assurance - Manufacturing - Root Cause Analysis – Project Planning – Statistical Process Control – Continuous Process Improvements – Project Scheduling – MS Computer Skills – Presentations – Visibility Charts – Estimating – Customer & Supplier Relations – Lean Initiatives – Safety – Training & Communications – 6S Initiates - Composite Bond – MRB & Dispositions – POSH Instructor – VISO Waterfall Charts

SERVICE DATES:

07/20/1973 to 1978 CESSNA AIRCRAFT COMPANY

10/05/1978 to 2005 BOEING COMMERCIAL & MILITARY COMPANY

02/16/2006 to 11/07/2008 L-3 COMMUICATIONS / CRESTVIEW AEROSPACE

02/15/2009 to 10/07/2015 GKN AEROSPACE ALABAMA

GKN Aerospace Alabama 2009 - 2015 Tallassee Al

Tool Process Engineer

Investigate RTE submittals from the floor Manufacturing Engineers for the request of fabricating Assembly, Detail or Tooling Estimates for Internal & External requirements.

Review the Tooling request from Engineering Drawings, Tool Drawings, Catia Model Base Definitions, Enovia DMU, DXF files, 2/ 3D Drawings, SCAR’s, ROI’s, NCR’s, Excel Spreadsheets & plan fabrication orders in CINCOM.

Submittals to outside suppliers with Cover Letter, Statement of Work & ECD for completion for response.

Create Routers for Internal & External Work Orders using CINCOM & SOPN/Oracle Database Forms for the Suppliers and Internal Tooling Shop.

Attend various Technical Meetings discussing Issues with all Customers – Honda Jet, Sikorsky, Airbus, Lockheed & Boeing

Communicate with the Shop floor with Production, Quality Assurance, Estimating & Proposals, and Configuration Management.

Provide Design studies for Estimating & Proposals for bids & future contracted work.

Ordering various materials & hardware for an Internal builds.

Create rough drawings and sketches for Build Concepts

Research all Customer related specifications

Visit various Supply houses for capabilities, capacity, advancements in technologies

Mfg Process Engineer

Oversee the Manufacturing composite work cells for Sikorsky products

Create RTE’s (Request for Tool Engineering) to the customer for new Tooling to support the manufacturing production line.

Use systems software Cincom to revise & create BOM’s, Sikorsky Supplier Portal, Purchase orders, Affectivities of aircraft. Disposition MDR’s (QA Rejections) for engineering repairs or scrap

Attend customer meetings to review issues and concerns from customer home base in Connecticut & Troy Alabama. Travel to supplier to address internal requests and issues and concerns

Review DR’s (Deficiency Reports) response with 5 Whys for corrective action & Fact Sheets

Initiate VIS (Vendor Instr. Sheet) to suppliers for nonconformities and engineering changes

Initiate Quad charts outlining customer C/A, Discrepancy, Root Cause and Cost Avoidance

Initiate Mfg Work Instructions for floor personnel and IMS inspection sheets for Quality Assurance.

Other systems DocPac (Blue Print), Cincom (BOM), Rag Chart (Excel Spreadsheet), DCC (Data Control), CFM, RTE, RFQ, ROI, RG’s (Return goods), Oracle, Tech Help submittals

Review Model Base Definition Detail & Assembly on Enovia

Tooling Program Manager – Honda Jet Program

Manager of Technical Engineering Department: Tool Engineers, Tool Designers & NC Programmers

Oversee all new fabrication of Design & Tool Fabrication from suppliers – Lay up Molds, Mill Fixtures, Bond Assembly Fixtures, Major & Sub Assemblies for the Honda Jet Program & Sikorsky Helicopters

Travel to suppliers to review and interact for managing on time completion schedules, Initial Quotes & Up charges, Communicate Corrections to Tool Designs for fit form & function, Conference calls back to GKN Tallassee for overall supplier commitments, percent completions and address issues and concerns that may cause impact to schedule, evaluation of product conformity to specifications

Geographic locations have consisted of supplier locations in Michigan, Minnesota, California & Georgia for composite tooling (Global, Visioneering, Mid South Machine & Tool, Smith Brothers, Remmele, Weber, Coast Composites & Treeco)

Support new technology and product development projects – manage conceptual modeling & designs for internal and supplier base design drawings

Weekly meetings via telecomm with Honda Jet & Sikorsky, located in North Carolina & Connecticut

DocPac, Cincom, Rag Chart, DCC & FAA, CFM, RTE, RFQ, ROI, RG’s, Oracle

Create Power Point Presentations, Provide Quality Assurance criteria, Project Flow Charts, 6S Initiatives and maintain satisfactory levels for the Engineering office area

Coordinate with floor personnel, production managers for nonconformities of new and existing customer tooling & processes improvements of manufacturing methods

Report directly to the Director of Engineering and the Deputy Director of Engineering & Operations

L-3 Communications 2006 – 2009 Crestview Florida

Product Support Manager

Manager of Technical Departments: NC Programming, P-Nesting, Tool Control Warehousing, Tool Engineering, Legacy Engineering Conversion (Modeling), Tool Design, Detail Fabrication, Tool Major – Jig / Fixtures & Tooling Quality Assurance

Manager of (3) supervisors, (78) floor & office personnel at L-3 Crestview Aerospace Communications facility – Committee Chairman for L-3 Periodic Scheduled Tool Inspections & Records

FOD, 6s, Ethics, EH&S, RFQ, OMTR’s, CBS forms, Recipient of PAR’s and CAR’s

Participate in Detail Manufacturing plans and Assembly plans on the production shop floor- to include visual aids & step by step manufacturing processes for sequential loads

ISO / AS9100 / Federal Acquisition Regulation (FAR Section 45) Tool Serviceability

Programs: Bell Canada, UH-1Y, CH-47, Gulf Stream, Boeing, Vought, Northrop Grumman & V-22

Manager of all customer tooling, introduced Serviceability Maintenance satellite shops (PM Shops)

Support new technology and product development projects – conceptual modeling & designs

Revise and Develop new Quality Assurance Procedures (QAP) and Work Instructions (WI)

Report to Director of Mfg & Technical Operations / L-3 Crestview Aerospace

Support Tiger Team initiatives assign subject matter expert personnel for nonconformities & Defect resolutions for the UH-1Y Huey program – Authority approver for New & Rework tooling

Responsible for Lean initiatives, Quality, Cost, Delivery, Safety, Morale (QCDSM)

Defusing critical customer situations & concerns, via tele-con, on-site and email

Process Failure Modes Effects Analysis (PFMEA)

Continuous Process Improvements of Customer supplied tooling and Government owned tools (GFE)

Work directly with DCMA & Bell Helicopter Supplier Product Assurance (SPA) for all Bell Programs – Active in weekly DCMA team communications & Policies/Procedures/Regulations -Review & Revise

Hold weekly staff meetings with direct reports and attend weekly Management Operation meetings-Ops

Member of Corrective Action Board (CAB) – Scrap Trend (SR&R) EH&S (Safety)Root Cause Analysis

Create / Present Power Point Presentations & Graphical charts for Actual & Estimate trends for ROI & daily efficiencies – Initiate Cost Justification for Capital Equipment & Manpower requirements

Provide Facility re-alignment plans for Mfg. and Technical departments (Capacity – Capability)

Created & Initiated New Job Descriptions to L3 Human Resources & Detailed specifications for the Technical organizations & employee goal evaluation mapping for hourly & salary personnel

Active participant in weekly Configuration Change Board (CCB) & Joint Change Board (JCCB)

Initiated & Revised Quality Assurance Procedures (QAP), Created Nonconformance Deposition Yellow Tool Tags and Process instructions for the Manufacturing Engineering department

Consolidated customer Period Scheduled Inspections PSI & PTI to L-3 QAP 015-003 PSTI procedure

Boeing Company 1978 - 2005 Wichita Kansas

Tooling Fabrication - Metal Bond- Team Lead

Breakdown and Fabrication of Composite Metal Bond Assembly, Detail Tools & 5S focal

Initiate Tooling On-Line Fabrication Orders, for internal and external process flows, Ordering of all T/R hardware & Investigate Causes for Corrective Action

Developed parametric estimates, detail estimates; conducted regression analyses and uses of other procurement cost analysis tools

Test for Vacuum Integrity of all Tools. Operate all shop machinery (Lathe, Mills etc.)

Implement and recommend process changes to Tool Design & Engineering drawings for fit, form and function. Nacelle, Fuselage, All New composite/invar tooling for the 787 Dream Liner

Administrative Management Assignments – Direct Reporting to PSM & Tooling Director

Inventory Management Analyst

Tooling, Manufacturing, Machine Shop & Facility Inventory Analyst

Excel database input for type, serial #, tracking #, bar coding, specific cost & location

Tooling Diversity Focal

Conduct meetings with managers & employees to discuss Diversity Principles Responsibility to establish a centralized conference room to occupy 50 Employees

Freelance Designer of Diversity Posters, Arrange displays for employee moral and participation.

Internal Self Evaluation Auditor - SEA

Conduct Monthly Self Evaluation Audits for Tooling, Quality Assurance and the Boeing Facility.

Principle audits of shop floor and office areas. (Lock Out / Tag Out; Hazard Communication; Confined Space) Internal focal for TPM, TPS and 5S initiatives

Implement and follow up of Corrective Action Memorandums submitted.

Assure Compliant with OSHA, EPA, NIOSH, ISO 9000 AS9100 standards and enforce PPE for all manufacturing areas.

Presented & Instructed monthly safety meetings for all tooling departments for proper PPE

Defect Resolution Team Chairman - DRT

Responsibility of (20) Investigators from all Tooling and Quality Assurance organizations, utilizing Root Cause Analysis & Investigations for Tooling & Manufacturing Nonconformities

Apollo Associated Services, INC. Nonconformance Management (NCM) Cognos, Computer Aided Process Planning (HMS/CAPP)

Develop & Maintain Excel Spreadsheets for daily open and closure activity of investigations.

Master Model Asset Reduction Chairman

Asset Reduction of Master Models from the Boeing Facility

Schedule weekly meetings with Facilities, Tool Coordination, MTDS, Quality Assurance, Transportation and Tooling Managers.

Develop and Present waterfall charts of current activities and estimated completion dates.

Assign action items to the responsible parties involved.

Geometry emerged to Computer Aided Three-Dimensional Interactive Application - Catia.

1998 - 2003 Manufacturing Engineer - ME

Create on-line planning (OLP) & Computer Aided Process Plans (HMS-CAPP)

Create Top Tool Objects in PDM (Product Definition Management)

Lead Authority of review/release of Detail Manufacturing /Assembly & Tooling plans on the shop floor-to include visual aids & step by step manufacturing processes for sequential sub & unit loads

Revise and update program management (PM) profile for continuous individual goals

Subject Matter Expert; HMS/CAPP, BAAN, NCM, BOM, DCAC / MRM & ERP.

Shop support for tool investigations for Tooling Core Business and implement shop floor processes for improvements. Initiate Special Orders and Deviations for Drawing Changes.

1997 - 1998 CQI Administrator – Team Leader

Establish processes for standardization and reliability and CQI goals using statistical quality control (SQC)

Familiar with D1-9000, Advanced Quality System, Data Entry for Cp-Cpk upper and lower values from Laser measurement data for process standardization

Established the First Standard, Stable & Reliable process for Aluminum Stretch Form Dies, Responsibility of Completion Stages I through V for Process Management Exit Criteria Checklist.

Cont on Page 4

1994 -1997 Tool Engineer Specialists - Offload

Liaison for Local Outside Suppliers; Coordinate outsource support

Worked RFIs submitted from Suppliers (Request for Information) Obtain and deliver all criteria necessary for build activities. Initiate Special Orders and Deviations for Drawing Changes

Communicate process improvements & oversee fabrication mythology: Travel 75%

Provide Tool Designs to suppliers for the fabrication of various thermoplastic vacuum tools

Coordinate with tooling suppliers for weekly progress and maintain production schedules

Have all tools transported to thermoform suppliers Lexan thermoform covers

Recommend process improvements for mythology of thermoforming various Lexan gage

Ensure suppliers had adequate stock of polycarbonate sheets in the multiple sizes and thicknesses

1993-1994 Tool & Die Lead

Breakdown man of Tool Shop

Order & Supply all components of build process

Interpret Engineering & Tool Drawings; Tool Planning & Sequencing

Fabricate Progressive Class-A-Mounted Dies & various detail and assembly Tooling.

1986-1993 Quality Assurance Corrective Action Unit- Investigator – Commercial & Military Programs

Team Lead Investigator Commercial/Military Division - CAU

Investigation of quality issues, Managed 30 investigators

Performance Management Reviews of personnel / CAU Investigators

Quality Control Inspection of Detail - Sub and Major Assemblies – First Article & Delta FAV/FAI

Special Equipment Used: Calipers, gage blocks, height gages, micrometers, scales, rules, bore scopes, surface plates, Computer Aided Three-Dimensional Interactive Application - Catia.

Investigation of Internal Withhold tags & Customer Trouble Reports for Root Causes; coordinate corrective action across organizations, Commercial Programs 747 (41 Section), 737 (Fuselage) 757 and 767 (41 & 43 Sections) final assembly structural investigations

Military Programs: Boeing / Northrop Grumman A-6 Intruder Composite Re-Wing Program, KC-135 Tanker structural detail and assembly investigations.

Quality Assurance Material Review Board Member – MRB

Investigation of Withhold Tags, Green lines / Blue lines / I & R / First Article Inspection (757 Cargo Conversion)

Travel to Suppliers for A-6 Intruder composite re-wing project – Jacksonville Florida & St. Augustine Florida Navel Base & local suppliers outside vicinity of Wichita Kansas

1978-1986 Tool & Die Maker – Lead man

Breakdown & Fabrication of Various Small Tools (Milling Fixtures, Boring Fixtures, Form Dies, Progressive Blanking Dies, Develop Layout Templates, Hydro Blocks Router tools & Saw Fixtures)

Interpret manufacturing planning, engineering and tool drawings to supply all necessary components for build process.

Precision measurement tools: Vernier Calipers, Hole Gages, Micrometers, and Height Gages etc.

Break down Tool Fabrication orders for shop personnel. Materials, T/R items and sequencing.

Cessna Aircraft 1973-1978 Wichita Kansas

Cessna Aircraft - Tool & Die Maker

Completed OJT- 16 week Tool & Die Maker apprenticeship program.

Fabrication of; Develop Layout Templates - Blanking Tools - Pierce Blank Dies – Class A-Progressive Pierce Blank & Form Dies - Form Dies - Hydro Blocks - Mockups for MR&D

Do all Hand Layout work from Engineering Drawings, Worked with Engineering Lofts and Tool Designs, Developed Spring Backs & Set Backs for Flat Patterns & Form Tools.

**Teaming:

Communications with all levels of management

Safety Monitor of all Tooling Organizations

Tooling team member in external Malcolm Baldrige assessment for Kansas Award for Excellence

Representative for the Tooling Dept. / Topeka Kansas, KAE award ceremony / Kans. Governor

Tooling Diversity Focal & Facilitator

CQI Administrator for Quality Assurance and Tooling organizations

Apollo Associated Services, INC. Root Cause Analyst

Developer of Defect Resolution Team (DRT) for Scrap, Rework & Repair, Established Histograms, Lean Initiates & Charts reflecting organizational skills & improved techniques to the current base line

Educate colleges, Tooling inquiries & Processes, Control Limits, Points, Analyze Catia Wire frame models & Solids

Self Evaluation Auditor (SEA) for all Tooling departments & Manufacturing area’s

Effectiveness & Efficiency Measures

Provide Communications with Local and Outside Suppliers, Oversee Records Operating Procedures & Policies

Job Aids Workshop

Quality, Cost, Deliver, Safety and Morale Focal (QCDSM)

SAFE instructor for PPE, OSHA regulations, NIOSH, Chemical & Hazardous Communications, Emergency Response, MSDS, NFPA labeling

Family participation day, schedule events and activities

**Summary of Education & Certificates from Business, Colleges & Universities;

-Machine Shop Certificate / East High Vocational School

-Kansas State High School Diploma – General Studies

-Wichita State University WSU – Aero Structures Engineering – 4 year program

-Southwestern College – Certified Quality Auditor / Quality Control Technology/Technician (CQA)

-Southwestern College - Member American Society for Quality Control

-Cowley County Community College – Associate of Arts and Science (A.A.S.)

-LA University (On-line Course Study) – Aviation & Engineering Technology - Associate of Science (A.S.)

-Management Development / ABLA Golden Eagle Training Center – Operations Management and Supervision Cert

-Okaloosa County Supervisors Training – Certificate

-Top Secret Clearance Obtained – International Affairs – Boeing Company – Lockheed Program

-Apollo Root Cause Analysis Methodology - Certificate

**Computer Experience:

MS Software – WORD, POWERPOINT, ACCESS, EXCEL, FRONT PAGE, PROJECT, MILESTONE, DIGITAL IMAGE PRO 10, MS PHOTO, OUTLOOK, PAINT, PICTURE MANAGER, VISTA

Business Software – POLP, CICS, HMS/CAPP, NCM, PDM, ERP, BAAN, COGNOS, CATIA

USA STAC, TEEM, NC-TSR, IMS, REDARS, VANTAGE by Epicor, Access CAR tracker system, Non Production Request ions (NPR) Production Action Requests (PAR), Cincom, Oracle, RTE’s, RG’s, CFM

Internet – INTERNET EXPLORER, NETSCAPE

Internet Email – EXCHANGE, OUTLOOK, INCREDI MAIL

Design Software - CATIA S-GLASS V-4 &5 DELTA CAD, VISIO, CORELIDRAW

Statistical Software - STATGRAPHICS PLUS, SPC, FREELANCE GRAPHICS

Other Products - POSTER-PRINTERY 4.5, STUDIO VERSION 9, PRINT SHOP PREMIER EDITION, PRINT SHOP PRESS WRITER, PHOTO EDITOR, NERO STARTSMART, ADOBE PHOTODELUXE, COREL PHOTO HOUSE, PRINT SHOP PREMIER 5.0, JAVA WEB START, STUDIO Version 9

**Education / Certificates / Training

*Transcript does not reflect 2001-2005 (276 additional credited hours of training)

1970 - Wichita Area Vocational Institute - Machine Shop

1973 - OJT / Cessna Aircraft / Tool & Die Apprenticeship program

1979 - Leika Laser Training

1986 - Pre-management Training / Golden Eagle Building, Wichita Kans.

1987 - Quality Assurance – Basic I & II

1988 - 2003 Catia V-4 Training / IBM Single Glass P200

1990 - Withhold Tag Training For Supervisors

1991 - CQI – Statistical Process Control - Continuous Individual Improvement - Idea System Training - CQI Member

1992 - Certified Mechanical Inspector

1993 - INCA Corrective Action - Blue Print Reading / Engineering / Tool Design – CQI / SPC for users - CATIA - Practice Lab / Solids / Advance Wire frame / Advance Draw / Basic Draw / Model Element Management / Basic Wire

1994 - CQI - Hardware Variability Control / HVC – Catia V4 Drafting Update

1995 - Kansas State High School Diploma - DCAC/MRM Learning Maps

1996 – Proper Relationships with Suppliers

1997 - DCAC/MRM Concepts For Define – Team Leadership Skills - Geometric Dim and Tolerance - Jobs Aids Workshop / Certificate / QTTP

1998 – Managing Manufacturing Plans - Benchmarking Certificate / QTTP - Phase 3 Process & Application Training For A/ I - PDM Inquiry - Tool Engineering Concepts - CQI Facilitator - Computing Security / Doing Business on the Web - Going Global With the Basics / IS Security - Options for Business Acquisition – Options and Module Logic - DCAC/MRM Impacts Customers Macro - MFG Views of the Product Structure – Modules - QA Numerical Control Process Model - 2 yr. Associate of Science Cowley County / Aviation Technology / – GPA 3.6

1999 - Catia Surface Basics / Drafting Techniques for Eng. / Solid Modeling / Construction Geometry / Model Interrogation - Questions of Integrity II - PDM Shop Training / Certified Quality Auditor Southwestern College – CQA

2000 - Tooling Precision Measurement-LASER - Quality You Are the Difference

2001 - Root Cause Analysis Certificate / Apollo Associated Services

2003 - Certified American Red Cross - CPR, AED & Standard First Aid -, Ethics Training / Graduate Degree -

2007 – Ethics Training Modular for L-3 Communications – Crestview Aerospace, 6 Sigma – Program Management Reviews (PMR)

2008 – Okaloosa County Supervisors Training Certificate – L-3 Annual/Monthly Ethics Training – Property Administrator for Government & Customer Audit Approvals – Preventative Maintenance & Records database – Business Unit Management (BUM) – Ethics Certifications – MS Excel Stages 1 thru 5

**Credited Achievements:

Awarded Outstanding Achievement for Administrator & Creator of the Defect Resolution Team for Scrap Rework & Repair for Quality Assurance & Tooling

Established & Maintained Continuous Individual Improvement goals for program management (PM) initiatives

Manage the Quality Assurance Corrective Action Unit

Achieved Level 3 in the Kansas Award of Excellence / KAE – Malcolm Baldrige National Quality Award

Instructor / Presenter of various Tooling Specific training programs

Safety Monitor for the Tooling Organization (Tool & Die, Plaster Pattern, Metal Bond, Jig & Fixture)

Certified American Red Cross - CPR, AED & Standard First Aid

OSHA Safety Awareness / Health & Safety Institute – HSI Facilitator

Initiator of vast Process Improvements for the Tooling Organization & Quality Assurance - TQM - CQI – SPC (Total Quality Management – Continuous Quality Improvement – Statistical Process Control - Benchmarking)

Compile Data for Graphical Stack, Line & Pie Charts for high visibility

Estimates, detail estimates; conduct regression analyses and uses of other procurement cost analysis tools

Awarded outstanding Team Leader for various tasks & accomplishments

Internal focal for TPM, TPS and 5S initiatives

Top Secret Clearance obtained for Military Programs / DPRO

Self Evaluation Auditor for the Boeing Company, ensure corrective action for hazardous situations in compliance with OSHA, PPE and EPA regulations & Manufacturing facility auditing (SEA)

Establish First Aid Stations through out the Boeing Campus

Manage the Quality Assurance Corrective Action Unit (30) investigators / Commercial & Military Divisions

Material Review Board Member – MRB (Quality Assurance CAU)

Work directly with Defense Program Review Officers (DPRO) & Federal Aviation Administration (FAA) personnel to present weekly Positive Root Cause Initiatives for Corrective Action and Line Unit affectivities

Direct Knowledge of aircraft structural systems – Major Assy., Sub Assy., Strut / Nacelles, & Detail Assy.

Engineering specialist to oversee build process of new Lexan acrylic covers for Fuselage Railcar transportation – Entry / Exit Doors, Fwd Nose Section, Aft Tail Section, Vertical / Horizontal stabilizers and Center Wing Box.

Special Equipment Used: Calipers, gage blocks, height gages, micrometers, scales, rules, bore scopes, surface plates & comparators.

Work directly with DCMA (Defense Contract Management Agency) and FAR regulations, Corrective Action Responses (Car’s) and Continuous Improvement Opportunities (CIO’s)

Develop Cost Analyst Work Sheets for Process Action Requests (PAR)

Work efficiency & daily job status of personnel to measure performance

Actively involved with ergonomics and HSI issues concerning safety

Establish Mile Stone/Project charts for processes and completion dates

Manage NC Programmers for Unigraphics, Solid Works for 2D & 3D modeling

Standardize process controls for Tool Control, proper tool storage, preventative maintenance

Improve water jet processes for feed / speeds and hold down methods for P-Nesting personnel

Attend weekly Operations Meetings for status & burn down charts of Tool Fabrication, NC Programming & Tool Control

Job Mapping and Individual Evaluations for all personnel & Managers for goals and step progressions

Establish and maintain working relationships with Employees, Customers and Vendors

Leadership Role in Personnel management

Ability to communicate clearly and motivate employees to reach their highest potential



Contact this candidate