Quality Assurance and Operations Management Professional
Midlothian, VA 23114
Quality and CI Manager Lumberg Automation a Belden Cable Company, Midlothian, VA, 2006 – 7/2009 – plant closed;
The hands-on quality leader for the manufacture, custom molder, assembly, and distributor of electrical connectors and electronic cable cord sets. Manufacture and distribute to worldwide market base precision industrial Ethernet users, automation, automotive, machine equipment builders, health & safety equipment, packaging, food & beverage, military, aviation and numerous other customer applications.
Winner of the BELDEN Global Corporate Values Award Program for “Team Work & Operations Improvements” on Sept 23, 2008
Established, implemented, trainer & hands-on leader of effective corrective action and prevention focus factory teams sustained zero manufacturing complaints from 60 per month and <30 PPM’s (reduction from 1000 ppm) and a total 99.7 % internal waste reduction of manufacturing nonconformance, defective product returns and warehouse shipping errors
Implemented & accomplished in 3 years of quality systems/lean enterprise continuous improvement actions leading to cost savings and /or avoidance cost of $1.0 million dollars annually
Developed & accomplished successful facility’s QMS upgrade in February 2009 with zero findings for the total recertification to the revised ISO 9001:2008 revisions.
Led, managed, established, trained & achieved through Kaizen events (value stream mapping, waste error proofing and standard work) improved operation index from negative (13.5) to positive 8.51% and improved production index from 48% to 80% efficiency
Managed, trained & coached the focused factory groups as quality steering committee leader reducing customer complaints 98% from 60 a month average in 2006 to 1 a month average 2008 and maintained zero product complaints for last 8 months of plant operations
Quality Assurance Manager Magna Donnelly Lowell, MI, 2003 – 2006;
Staff manager actively led and developed quality initiatives for high volume $150 million in sales. OME injection mold, class “A” paint to body color match and intricate automotive assembly of exterior automotive and light truck mirrors and door handles. Directly manage 5 quality engineers, 2 field quality engineers and 3 quality technicians in a 3 shift operation.
Implemented, achieved and maintained ISO: 2000 - TS16949 certification after hire as the first Magna Donnell facility to achieve certification CY 2003 and sustained excellent audit surveillance performance CY 2004 & 2005
Managed actions, led tracking & received (Lowell division) the Toyota NA customer satisfaction “Most improved Supplier Award” in 2006 for performance improvements in CY 2005
Eliminated 95% of containment cost of poor quality $800,000 in a year and a half with focused problem solving, supplier chargeback and quality budget counter measures with action driven tracking program. I developed, established and managed this program
Managed & led the actions to graduate from GM Top Focus program within 7 months and sustained a “green status bid list” thereafter
Developed & led the actions that reduced the overall total customer PPM performance by 75% within first 6 months and maintained further 30% to 50% improvement reductions for both CY 2004, 2005 & 2006
Led the effective standardized Layered Audit Process scheduled and integrated into mold, paint, assembly, control plan & FMEA
Implemented, led and managed the reduced cost of quality by $625,000 with quality department head count reductions - from 22 down to 13 direct reports and other direct department CI initiatives.
Directed & led design-of-experiments improvement activities with lean CI waste reduction for molding, painting and assembly by $750,000. Established and led daily scrap reduction material reviews and I provide training & coaching for counter measures
I Improved required product gauge capability by performing SPC tooling/product studies and PM. And I established easy to follow shop floor visual management system using autonomous gauge and equipment standard work instructions reducing cost, sample frequency and improving overall capability
Continuous Improvement & Quality Assurance Director BLD Holland, MI, 2001 - 2003;
I Directed, developed, implemented, trained, coached QMS and Lean/Six Sigma/CI for the total operations that optimized quality, manufacturing, purchasing, material control and distributions systems & processes. Facilities - 1, brass and steel screw machine and CNC manufacture of air brake components in Bucyrus, Ohio, 1, injection molding and assembly operation in Ocala, Fla. Headquartered as director at our CNC machining & assembly Engine Controls Parts Producer Facility in Holland, Michigan BLD/Sloan Industries.
Implemented, achieved and maintained the successful initial certification of ISO: 1994 - QS9000 and sustain 3 years of successful surveillances for 3 manufacturing locations
I published from actions & performance the multi facility monthly kaizen events, customer satisfaction scorecard and companywide continuous improvement initiatives that averaged $500,000 in annual savings
Developed actions that reduce cost of poor quality by $ 500,000 in one year and increased production output by 30%
Managed the improvement actions eliminating 90% of monthly customer complaints in one year caused by manufacturing, supplier & shipping errors
Directed and Led design-of-experiments improvement activities reducing machining and assembly waste by $250,000
Established, trained, implemented and maintained complete Lean Continuous Improvement program & managed self directed teams
Warranty Systems Manager Ford/ZF, Batavia, OH –Transmissions, 2000 – 2001;
Managed and supervised three Quality Engineers, Two Customer service Specialists, Six UAW Technicians, and Two UAW Mechanics. I provided analysis of customer claims, performance trends and manufacturing final quality audits on V6 automotive transmissions. I managed 8D problem solving teams, hardware analysis, statistical process control charting, capability studies and training, product line audits, directed shop floor quality union & supervision meeting and document area continuous improvement actions.
Internal QS-9000 team leader auditor that supported the initial QS9000 facility certification in 6/01
Established, developed & directly provided Japanese, European and domestic customers with six sigma and 90 day improvement project plans and meetings
Responsible & successfully completing the closer of pervious open and late eighty-seven outstanding quality nonconformance customers complains. I completed the 87 customer counter measures and approved within 60 days and sustained zero reoccurrence
Responsible for preparation & presentation of monthly management & Ford Motor Corp. reviews. I established effective standardized management review outline reducing pervious meeting time by 50% and allowing for new “Gemba” plant tour. This improved management understanding of counter measure/CI actions and allowed direct CI input combining Ford Motor engineering
Director of Quality Assurance Plastic Trim, INC. Beaver Creek, OH, 1997 – 2000;
Director of Quality Assurance to four facilities for a $100 million OEM Automotive supplier, providing extrusion and injection molded window reveal trim, body side protective and decorative trim and interior functional components. Oversaw and directed thirty-five direct and indirect employees Quality Managers, Quality Engineers, auditors, laboratory supervisor, lab technicians, and project managers.
Managed the laboratory certification / qualifications/ validations of materials and finished product – saving $300,000 annually from outside testing
Established outside MFG facilities quality continuous improvement plans & material reviews that led to a $75,000 monthly reduction in non-value added inspection and sorting
Leader of quality system, lean focused factory improvements, improved quality plans, calibrated cosmetic acceptance standards, standard work with CTQ’s and my strong & effective hands-on customer satisfaction leadership reduced monthly PPM’s from 15000 down to less than 100 PPM in less than one year
Reduced the average total customer concerns from over 15 to less than 2 per month in one year
Established and led the initial ISO:1994 - QS9000 programs for two outside finishing locations and both certified in 1999 reducing annual intercompany shipping cost by $250,000
Quality Assurance Director Como Products, Columbus, IN, 1993 - 1997 and concurrently, LDM Canada, Leamington, Ontario;
Quality hands on director of one unionized plastics custom products manufacturer, medical device (GMP compliance) and automotive Tier one high volume custom molder for interior and exterior color matched JIT auto and non-auto (GMP, Medical, & Electronic Computer Industry consumer goods) products. Managed and directed all Quality systems for two-injection molding, painting, decorative trim, functional component assembly, and operation facilities.
Received Black Belt six-sigma certification from GE as only the second outside supplier at that time to do so
My Six Sigma Black Belt programs were for six new functional/decorative refrigerator handles from thirty-six gas-assist injection molds. These program added the value of $15 million in sales and $7 million in savings to GEA
Established , implemented as hands-on led auditor/trainer, achieved and maintained initial ISO: 1994 – QS9000 certification for both US & Canada operations during CY 1994
Responsible for removing several customers imposed high cost containment activities with our Canada Automotive plant as Director reducing and avoiding cost of $200,000 & improving the sustain customer satisfaction improvements
Quality Assurance Manager Precision Plastics Crawfordsville, IN, 1989 – 1993;
Managed and directed all Quality systems for an injection molding assembly operations facility for Medical & electronic Computer Industry consumer goods. I directed multiple programs to reduce returned good from 10% to .8% for a $300,000 savings the first year. Performed screening experiments on 50% of our target customer’s products and established operator process control charts on each job. I initiated statistical data gathering to diverse value added process such as painting, aluminum vacuum, deposition, ultrasonic welding, and assembly. Established first ISO compliant quality manual and audit program certified to ISO and QS9000 requirements
Quality Control Manager C.R. Industries, Hobart, OK, 1984 – 1989;
Quality manager for an automotive, aircraft, and heavy truck engine & shaft seal molding, metal preparation, packaging & chemical treatment facility. Managed & directed a new Quality department of 15 auditors, 5 Q.C. lab technicians and 1 statistician. Received the Ford Motor North American Automotive Operations Q1 award. Received the Saginaw Steering Gear USA/ Europe excellent rating. Received the Chrysler Penta Star Award (1987). Received GM Spear 1 rating on preferred supplier’s list. Managed & maintained the laser/ video data acquisitions computer network systems.
Quality Control Manager Barr Inc. Sandusky, Ohio, 1980 - 1984;
Managed and directed all Quality systems for an automotive and non-automotive rubber molding, mixing, rotational molding, sponge molding and decorating facility.
Professional Development Certification, Education and Training Experience Skills;
Certified Quality Engineer of the American Society for Quality Control
Six Sigma Black Belt training and certification program with General Electric Appliance; Minitab trained
Toyota “TPS” Toyota Problem Solving techniques certified; Toyota “Pulse Rate” Management Metrics & Audit tool trained;
Certified to Toyota Production Systems Training – Toyota Cambridge ONT and Toyota IN
Third Party certified Lead Auditor to provide TS16949 and ISO 9001:2008 internal auditors, supplier training & strong understanding of ISO 14001
Internal Lead ISO/QS Auditor Training ISO:19011 certified to train the trainer – Plexus Corporation
Excellent strengths developing complaint quality manuals, procedures, process maps, management reviews , work instructions quality control plans & auditing systems
Lean Management Certified, Lean Management Laboratory Company, Ltd., Magna Intl & Belden Cable Certified Lean Program
Quality Control and Statistical Process Control, Maynard Achievement Center
Advanced and applied statistics & process capability (S.P.C.) American Supplier Institute, Inc.
DCX - Shainin @ Executive Strategies trained; GM - Red “X”@ trained
Experienced hand-on competence for DFMEA, PFMEA, Risk Priority, Dynamic Control Plans & Standard Work instructions implementation and sustainment
Experienced to provide DMAIC, DMADV, DOE and PDCA Six Sigma focused training methodologies
Competence for establishing, training and completing APQP, PPAP & ISIR customer related submissions, documentation, product retention and continued compliance and improvement
Gauging equipment, various calibrations software and machine calibrations and R&R analysis
Corrective Action and Countermeasures experienced – Toyota, Honda of America, Ford Motor, GM, Chrysler & various others
CAPA - Diverse background developing, improving, training, leading shop floor, departmental, key suppliers, product/process problem solving & counter measures. Establishing effective tracking systems to monitor reoccurrence and data collection
Team oriented problem solving, Quality Operating Systems, Ford Motor, GM, Toyota & Chrysler & Analytical Warranty Systems. Experienced & have developed, established effective training to internal operations and key suppliers
Experienced with various major customer interactive metric, communications & information websites
Leader, hands-on implementer, provider, trainer of Quality-Cost-Delivery-Safety balanced scorecard, BOS, TQM, QMS, KPI, CPM, Operation Excellence, Shop-Floor Area Experts, Hour-by Hour, Standard work & Matrix Operations Boards
Creative practical strong experience in Strategic Operations Lean Enterprise cost of quality, error-proofing, S.P.C. capability control charting, quality control plans, standard work sheets, 5S, value stream mapping, KPI performance & safety for warehouse, operations shop floor and support areas. Establishing, implementing, effective easy to follow daily/weekly/monthly visual management charting providing real-time performance and counter measure when required
GE gas assisted/resin injection molding technical program – experienced range small to large ton machines with mutable shot, gas-assist, and insert molding
The Science of Color Matching, certified visual cosmetic management paint and plastics mixing – Atlanta Ga.
Trained with various painting, plaiting, surface preparations and applications processes for various plastics and metals
Metal forming, machining and assembly trained with practical quality operation & safety understanding of various CNC, screw machine, stamping, die cast, forged, welding, quality performance test equipment and process improvements
Design of Experiments certified, Eastern Michigan University
Experienced and effective with union and nonunion organizations with multicultural quality, engineering & lean manufacturing special training communications using simple work standard/quality plan illustration guidelines & visual management skills
Experienced with IPC, IEC & CEI quality and workmanship standards – electrical, electrical testing & solder
Clean room and ESD quality controlled systems certified by Hewlett Packard, IBM & Lexmark
CAD Training Magna International
CMM Training &GD&T Training Mitutoyo, Brown & Sharpe and Zeiss
Total Quality Management & Train the Trainer program Motorola & Ford Motor
JIT, inventory control and material flow systems ERP, MRP, SyteLine trained – material control equipment trained and experienced
Proficient - Excel, Word, Power Point, Project, Visio, Access, Outlook Lotus Notes various other quality software & inventory systems
Education University of Akron, Ohio 2 years - Geology, Chemistry and Math. Would consider pursuing completion of my remaining academic hours for a B.S. degree in Business Management and/or Engineering if required and with company supported continued education contributions.
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