Manager Quality Assurance

STEVEN McDONOUGH

** **** ***** **** 256-***-****

Muscle Shoals, AL 35661 Cell 256-***-****

*******@***.***

Professional Summary

Many years experience as Senior Management in Automotive and Industrial

Manufacturing area. A vast background in: Plant Management, Engineering,

Quality and Japanese Production Systems and Lean Manufacturing. Proven

success implementing new processes, new products, and quality programs;

including, Q1, ISO 9001 and TS16949.

Professional History

North American Lighting-Koito Group July 2012 - Current

NAL - Muscle Shoals, Alabama

Assistant General Manager, Automotive Lighting, Headlamps / Rear lamps

. Responsible for Plant Operations of the 1100 Team member

facility. Currently overseeing two plants; Head Lamps, and Rear

Lamps with Plant 3 under construction with an expected SOP of

January 2014.

. Production processes include: Injection Molding, Coatings, and

Assembly. Responsible for Annual budgets, Manning, Detailed

Planning, Plant Operations; Direct Management of 7 Department

Managers.

. Managed a 300% expansion of our Head Lamp Operations from; 4th

Qtr 2012 to July 2013.

. Launching 16 New programs for Nissan, Honda, Toyota in 2013 and

preparing for 7 additional new programs launching in our new

Plant Expansion from Jan-July of 2014.

Johnson Controls Incorporated July 2011 - July 2012

JCI - Automotive Excellence Seat/Interiors Division - Plymouth Michigan

Corporate office

Responsible Multiple Locations - West Point, GA, Murfreesboro, TN

Director, Continuous Improvement and BBP (Best Business Practices)

Nissan/Kia Business Unit

Responsibility Level: Working under the framework of Johnson

Controls Continuous Improvement and BBP system, set direction

for strategic and operational goals for the operations unit.

Work with the operations leadership team to meet or exceed CI

and BBP cost and quality goals through methodical review and

process improvement. Direct and resource CI teams to ensure the

operational plan and the unit's annual and strategic objectives

are met.

. Typical Duties: Develop, implement, continuously challenge and

monitor the Operations Unit Continuous Improvement roadmaps to

drive hard savings, cost avoidance and quality improvements as

efficiently as possible.

. Hiring, succession planning and people development for Master

Black Belts, CI Managers, Black Belts, Green Belts and Lean

Implementers

. Drive Lean manufacturing in operations and in new launches.

. Maintain and improve BBP (Best business practices) metrics

across all plants and product lines within the Business Unit.

. Leverage best practices by conducting leadership benchmarking to

Best-In-Class operations.

Akebono Brake Corporation February 1997 - July 2011

Akebono Brake Corporation - Glasgow facility March 2005 -Current

General Manager/Plant Manager - Automotive Disc Brakes (Pads and Calipers)

. Manage a 750 Team Member Multi-plant/Non-Union Facility; which

includes: Production, Engineering, Purchasing, Sales, HR,

Finance and Quality. Profit center facility with full P&L

responsibility.

. Manage annual sales of $300M, supplying product to GM, Toyota,

Ford, Chrysler, Hyundai, Nissan and Mazda

. Improved Safety Index by 75%, benchmark with in Corporation.

. Maintained lowest safety index globally. 300% below state

average

. Managed an 88,000 sq. ft Expansion to produce Disk Brake Pads

for After Market

. Improved Operating Profit by 21% from 2009 to Current

. Improved Aftermarket Plant profit from negative $.5 million to

positive $.4 million in one month

. Currently meeting budget with 12% year over year task.

. Understand all aspects of Manufacturing and Production systems

and works with all aspects of the Toyota Production System; such

as, Kanban, Jidoka, JIT, Standardized Work and Kaizen workshops.

Manufacturing Manager - Disc Brake Pad Manufacturing February 1997

- March 2005

. Responsible for 350 Production Team Members, including

Manufacturing Engineering, Plant Maintenance, and MRO Purchasing

while utilizing JIT, Kanban (pull system), standardized work and

small team Kaizen activity.

. Worked directly with Human Resources, Marketing & sales, to

plan, staff and start up a 4 Module Capacity Expansion project;

which allowed an additional 2.5M pieces/month

. Reduced Defects by 60% and improved Productivity by 45% as our

product line grew 10x.

GATES RUBBER COMPANY October 85 - February 97

Galesburg Illinois Division (Union Facility) - July 96 - February 97

Manufacturing Manager - Automotive and Industrial Hose Manufacturing

. Responsibilities included: profit and loss, budget preparation,

Product Control, Customer Order service, Purchasing, and

Maintenance for the Hydraulic Coupled Assembly Plant.

. Worked with 500 Team Members to reduce standard cost by 3% on 50

million $'s in sales through a 45% increase in assemblies per

man hr and a 75% reduction in Quality rejects

. Implemented Cellular Manufacturing and introduced a new Quality

Assurance program that reduced Customer PPM by 32%

Red Bay, Alabama Division (Non-Union Facility) - October 95 - July 96

Plant Manager - Heavy Duty Reinforced Industrial Hose

. Responsible for every aspect of the Manufacturing Facility;

including Human Resources, Quality Assurance, Accounting,

Purchasing, Planning, Engineering and Production

. Directly involved in negotiating $200,000 of Material cost

reductions from Vendors

. Worked with Corporate HR to complete the Wage and Benefit

survey, which resulted in a positive change in our Medical Care

Provider

. Implemented Waste reduction teams for administration and

Production resulting in labor reductions for accounting and

accounts payable, 2.5% standard cost reduction in Production;

which included a 33% decrease in scrap & defect.

Charleston, Missouri Division (Non-Union Facility) - January 93 - October

95

Quality Assurance Manager/Production Manager (dual role) - Long Length

Automotive and Industrial Hose manufacturing

. Responsible for Quality Assurance Department, Hose Test Lab, and

Hose Production

. Completed 10 customer audits, including Ford Q-1, Nippondenso,

and Freightliner achieved A2LA Lab accreditation

. Worked with 200 Team Members to plan, engineer and implement a

new curved hose product line using Cellular Manufacturing

concepts

Poplar Bluff, Missouri Division (Non-Union Facility) - December 90 -

January 93

Area Manager - Automotive and Industrial Curved Hose manufacturing

. Supervise, plan and execute Production using Focus Manufacturing

Teams

. Direct supervision for 3 supervisors and indirect supervision of

80 Team Members on 3 shifts

. Work directly with MRP, Customer Order Service, Materials and

Planning to ensure product demands are met

. Successfully implemented Cellular Manufacturing, reducing Work-

In-Process by 90%, floor space 60%, and Variable Manufacturing

cost by 3.5%

Line Supervisor - October 85 - December 90

. Responsible for encouraging and developing 30 Team Members on 1

shift. Established extrusion profiles using standardized set-

ups and SPC

. Team Leader of the Extrusion Solution Team, which focused on

Continuous Improvement.

Qualifications:

. An innate desire to succeed and help others to succeed

. Successful in presenting and selling ideas to top management

. Proficient in normal office computer programs

. Experience developing and managing budgets

. Demonstrated flexibility in all job responsibilities

. Proven track record developing and implementing new ideas for cost and

quality improvements and new product implementations

. Proven track record working with all levels of the company

. Experience in 3 Plant Expansions

. Experience in new product development and Plant start up of

Aftermarket Division

. Managed implementation of Ford Q1, ISO 9000 and TS16949 and other

quality programs

Academic Credentials

Southeast Missouri State University, Cape Girardeau, Missouri - Business

Management

Woodfield University, BS Business Management

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