Engineer Quality

JOHN E. KETCHEM II

* * * * * . M u l l i g a n Av e n u e

Chicago, Illinois 60646

Cel l 847-***-****

Home 773-***-****

joh nketchem@s bcgl obal. net

http://www.linkedin.com/in/johnketchem

Summary of Experience

A results-oriented professional in Customer Technical Service/Quality Assurance with over 20 years of hands on experience in

a wide variety of production environments. Certified by the American Society for Quality and highly skilled in the

development and implementation of plans to meet/exceed goals and objectives. A motivated, flexible individual with a

businesslike approach to the job. Recognized by management and customers for building and maintaining strong and lasting

relationships and possess a thorough understanding of the Toyota Quality System with a unique understanding of the Japanese

automotive professional culture. International Travel to Japan and Canada.

Core Competencies

Supplier Development Problem Solving Employee Training/Development

Control Management SPC/PPAP/APQP/FMEA Customer Satisfaction

Technical Troubleshooting Team Building Strong Communication Skills

Contract Consultant Between Full Time Employment – See Page 3

QCC LLC Harwood Heights Illinois

2/2013 to 5/2013

Supplier Quality Engineer Consultant

. Reported to the Quality Manager. Responsible for Improving and controlling the quality of 200 suppliers in the

categories of Machined Parts, Castings, Heat Treating/Plating, Stamping and Grinding. International Organization

Standardization TS

16949/ISO9001:2000/ISO 14001

• Served a key role in selecting and launching supplier scoring program. A quality management and rating

system for suppliers scorecards based on PPM, on time delivery, corrective action response time.

• Updated the company Supplier Manual to coincide with the new rating system.

• Responsible for all suppliers Return Material Authorization credits for defective material and cost of quality.

PERFECTION SPRING AND STAMPING, Mt. Prospect Illinois 7/2012 to 10/2012

Manufacturer of subcomponents for automotive.

Quality Manager Consultant

• Responsible for daily Quality of production, All Quality functions as needed. Monitor and report PPAP progress

and new product launch.

• Responsible for leading and facilitating positive results for TS Audit, no Major or Minor findings

• Corrective action responses 8D and 5why. Must report Monthly to Upper Management and all

employees in a stand up meeting in the following areas using data in Excel, Customer Score card,8D corrective

actions, Hold area Inventory, Monthly Rejections, Internal Defective Part Per Million (D- PPM ), Scrap Detail,

Vendor Performance. Interface with customers and communicate with team as needed daily.

TOWER AUTOMOTIVE, Chicago, Illinois 7/2011 -3/2012

Tier one supplier to Ford Robotic Welding and Stamping

Quality Engineer/ Supervisor,

• Responsible for daily Quality of production. Supervise 4 departments,

• Weld Destruct, CMM Operations, Inspection, and Weld Repair

All Quality functions as needed. PPAP documentation, launch of new product and production lines.

JOHN E. KETCHEM II PAGE 2

• Destructive and Nondestructive testing for weld penetration. Corrective action reports. Plant Meetings daily as

required.

SENIOR FLEXONICS, Bartlett, Illinois 1/2008 – 1/2009

$125 million manufacturer of automotive welded exhaust components, high pressure diesel fuel injection

systems and Exhaust gas treatments. International Trucking, Caterpillar, 450 employees, Domestic

Travel.

Supplier Quality Engineer/Supplier Development. Reported to the Quality Manager. Responsible for

Improving and controlling the quality of 254 suppliers in the categories of Machined Parts, Castings, Heat

Treating/Plating, Stamping and Grinding. International Organization for Standardization TS

16949/ISO9001:2000/ISO 14001

• Served a key role in selecting and launching IQS supplier website. A quality management and rating system

for suppliers scorecards based on PPM, on time delivery, cost of quality, corrective action response time.

• Authored company Supplier Manual.

• Traveled to suppliers’ locations and communicated with design engineering to launch new products. Audited

suppliers’ process and procedures, and supplied validation reports for products manufactured.

• Supplied PPAP approval and pre-audited for new business working closely with the Purchasing Manager and

Buyers.

• Approved all DFEMA and FMEA and Control Plans submitted by suppliers

• Implemented APQP documentation and AIAG format requirement for all PPAPS submitted to speed up

approval times and consistency of PPAP packages

• Recaptured $112K in supplier debits in two months. IQS system was projected to recapture $600K to one

million four hundred dollars per year in overall Cost of Quality.

• Worked with supplier’s processes applying continuous improvement techniques utilizing poke-yoke, SPC

data results. Audit process improvements and closure of non-conformances.

• Championed the initiation of proper corrective action with effective timely supplier reaction/feedback.

• Mentored and advised JR. Quality Engineers, Lab Technicians, and Inspectors.

• Worked closely with purchasing department to implement new contractual agreement plans with current and

future suppliers. Enabling the new Supplier Quality Manual to become gradually implemented and recapture all

documentation fees for corrective actions, sorting cost, scrap cost and transportation fees.

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10/2006 – 04/2007

SEMBLEX CORPORATION, Elmhurst, Illinois

A manufacturer of fasteners for automobiles and commercial use, including Bose, Lear and John Deere.

Tier One Supplier for Chrysler, Ford and General Motors. International Standardization Organization

TS 16949/ISO9001:2000/ISO 14001.

Senior Quality Assurance Engineer Supplier Development . Reported to the Vice President of

Quality/Vice President of Operations. Responsible for improving and controlling the quality of 77

Suppliers within 4 categories consisting of Heat Treating/Plating, Wire, Purchased Parts and Sub

Components for international and domestic suppliers.

• Communicated with all suppliers regarding defects and maintained Supplier Development Monthly Report

Card.

• Provided supplier technical support concerning customer quality issues.

• Built a strong working relationship with all suppliers, audited suppliers and issued Quality Problem Reports.

03/2002 – 04/2006

FUTABA INTERNATIONAL AMERICA CORP., Carol Stream, IL.

Manufacturer of Stamped Stainless Steel, Galvanized and E-Coated, Robotic welding, automobile components.

Tier One supplier Toyota Motor Manufacturing America (TMMA), Mitsubishi, Honda and

General Motors. TS 16949/ISO9001:2000/ISO 14001

International Travel Japan and Canada customers and suppliers

Supplier Quality Engineer. Responsible for creating Quality Supplier Development Program

• Led corporate effort to recapture $800,000 annually from sort, rework and scrap.

JOHN E. KETCHEM II PAGE 3

• Managed all company international/domestic suppliers and DPPM grading system/ranking.

• Audited suppliers, issued Quality Problem Reports and monitored counter measure effectiveness for

recurrence.

• Show supplier improvement in monthly supplier reports to management.

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Quality Assurance Engineer. Responsible for acting as primary contact to Toyota Manufacturing Canada, handling

all customer technical support/quality issues.

• Provided technical support for Toyota Manufacturing Kentucky (TMMK).

• Supervised and trained Six Quality inspectors.

• Interacted with Japanese, American and Canadian Toyota Quality Team members.

• Managed required TMMA Quality Program documentation utilizing Toyota Quality criteria as stated in

Toyota Supplier Quality Assurance Manual.

• Resolved customer technical service/quality claims at Bloomingdale facility, Toyota Motor Manufacturing

Canada, Mitsubishi, General Motors, Toyota Lexus and Honda.

• Primary contact for Toyota claims resolution and Mitsubishi PPAP, FMEA, CONTROL PLANS for

production approval process of new product lines.

• Approved the new manufacturing lines and all prints/fixtures before shipment. Report all statistical data

results from production using Mini Tab.

4/1997 – 12/2001

U.S. CAN COMPANY, Lombard, Illinois

Manufacturer specializing in food and chemical containers. ISO 9000

Quality Assurance Manager.

• Responsible for performing and handling all internal/external audits.

• Handled customer alerts/complaints and resolved non-conforming materials/product issues in a timely, cost

effective and customer satisfactory manner.

• Reorganized Quality Department, including procedures, GMP, specifications and documentation in

preparation of an independent audit by AIB International Department of Food Safety and Hygiene where the

company received a Superior rating, a first in company history.

Quality Assurance Engineer. Responsible for quality of production and monitoring all lines

• Performed periodic testing of product utilizing a variety of testing instruments, including Rockwell

Hardness, Micrometers and SPC charting.

• Reduced customer defects complaints for a filler company by 50% and was awarded the #1 supplier by the

company.

• Internal ISO 9000 Auditor

• Worked with R&D Department to reduce spoilage and customer complaints by 40% through the integration

of a new application.

• Created customer alerts and complaints newsletter that flagged potential problems, resulting in a 30%

reduction in spoilage rates.

ADDITIONAL WORK EXPERIENCE – Contract Consultant between Full Time Employments

CURTIS WRIGHT CORP. Metal Improvement Div. Addison, Illinois – Quality Manager

Quality Manager Consultant

Shot peening for Aerospace and heavy equipment, service industry, NAFTA ISO 9001

Responsible for daily Quality of production. Supervise technician’s daily inspection duties

And all Quality functions as needed. Tracking internal corrective actions, and responding to external cars.

Reporting quality in quarterly meetings. Customer relations and communication.

ITW KESTER, Itasca, Illinois - Quality Consultant Engineer

Manufacturer of products for a wide variety of industries, Metals and Paste products for Circuit boards

Automotive and Intel.

JOHN E. KETCHEM II PAGE 4

INPLEX CUSTOM EXTRUDERS LLC, Des Plaines, Illinois - Quality Consultant Engineer

Manufacturer of products for a wide variety of industries: appliances, defense, packaging, construction, signage and

display, wire and cable, conveyors and automotive.

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PEERLESS MOUNTS Inc. Melrose Park, Illinois - Quality Consultant Engineer

Manufacturer of audiovisual mounts for residential and commercial markets.

AMD INDUSTRIES, Inc., Cicero, Illinois – Quality Consultant Engineer

AMD is a leader in designing, engineering, manufacturing and assembling of custom POP displays and

merchandising equipment/systems in USA, Canada and Europe.

ILLINOIS TOOL WORKS - Elk Grove Village, IL - Metallurgical Quality Lab Consultant

Manufacturer of fasteners for automobiles and commercial use

EDUCATION:

B.S., Major: Quality Management, Gordon University, Bradenton, Florida-2004

Engineering/Metallurgy/Metrology/Manufacturing Technology Courses, Elgin Community College, Elgin, Illinois - 2000

Math/Engineering Courses, Harper College, Palatine, Illinois - 1996

CERTIFICATIONS:

Supply Base Management - 2001 Statistical Process Control - 1997

Pilgrim Quality Software, Supplier Focus - 2001 ISO/QS 9000 Overview & Implementation - 1997

ASQ Certified Mechanical Inspector - 1999 American Society for Quality, Fox Valley Section 1208

ASQ Certified Quality Technician - 2000

Quality Technology & Metrology - 1998

COMPUTER

SKILLS:

Microsoft Office, Word, Excel, Power Point, IQS Quality Software, CMS System

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