Quality Engineer

Carl E. Wilcher, Jr.

*** ***** ***** **** - *****, TN 37058 (Cell) 931-***-**** (email)

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

Work History:

Akebono Brake (Formerly Bosch Brakes) - Clarksville, Tennessee

JIT Tier 1 Manufacturer of brake drum, rotor and caliper assemblies for the

automotive industry (GM, Chrysler, Ford, Nissan, and Toyota).

06/10 to Present Supplier Quality Area Leader

. Lead Clarksville supplier quality team (3 Supplier Quality Engineers and

1 Quality Technician) to achievement of policy deployment goals.

Actively participate in policy deployment and management review meetings.

. Prepare and report supplier quality metrics. Identify and implement

countermeasures for metrics that are negative to goal.

. Plan, coordinate, and conduct technical assessments, quality system

audits, and process sign-offs ensuring compliance to internal company

standards and customer specific requirements.

. Resolve supplier incidents. Develop containment activities and coach

suppliers in implementation of both process and system countermeasures as

applicable. Ensure satisfactory completion of the corrective action

documentation in a timely manner. Communicate containment and corrective

actions to the internal teams affected by the incident.

. Provide technical support to assist suppliers with preparation of APQP

documentation.

. Review and approve supplier PPAP documentation.

. Document and process cost of poor quality charges for supplier incidents.

Work with purchasing to recover associated costs.

Tennessee Stampings LLC - Portland, Tennessee

JIT Tier 2 Manufacturer of metal stampings and welded components used in

the automotive industry.

04/09 to 12/09 Quality Engineer / Quality Manager

. Implemented actions to reduce external PPM from a historical average of

132 PPM per month down to 0 for 3 consecutive months May, June, July,

2009.

. Negotiated reductions in PPMs with Tier 1 customers and implemented

system for faster responses and closure of corrective actions.

. Successful presentation and removal of TSL from Tenneco SIP program

. Improved Corrective Action responses, initiated EPC and Hold processes.

. Management Representative with responsibility for TS16949 internal

auditing and compliance

. Internal Training and participation on Lean Manufacturing; 6-Sigma, and

5S Teams

. 4 direct reports (quality engineer, quality tech, TS-16949 coordinator,

document control)

TGASK - Hopkinsville, Kentucky

JIT Tier 1 Manufacturer of Automotive window, door, and body seals for

Toyota, Honda, Nissan and Ford.

12/05 to 04/2009 Quality Coordinator (responsible for quality

engineering and platform engineering)

. APQP documentation (PFMEA, Control Plans, Inspection Instructions,

Testing Methods & requirements)

. Customer PPAP submissions, customer visits, supplier visits, supplier

auditing, monthly reporting, corrective action reviews, and review and

approve supplier PPAP submissions

. Introduced multiple process improvements / cost savings ideas totaling

$459,000 per year

. Reduced warranty claims from $11K per month down to $2K per month and

quality rejects from 16,743 PPM per month to 25 PPM for 12 Months, 19 PPM

for 6 Months, and 9 PPM for 3 Months.

. Submitted evidence and achieved Q1 Endorsement from Ford Hermosillo Plant

06/30/08

. Generated an Annual savings of $1,018,020 in manpower optimization and

component part savings

. ISO-14001

ThyssenKrupp - Hopkinsville, Kentucky

JIT Tier 1 Manufacturer of metal stampings and welded components, engine

cradles, rear suspension cradles and trailing link assemblies for Mazda,

Ford, GM.

07/04 to 09/05 Quality Engineer

Douglas Autotech Corporation - Hopkinsville, Kentucky

JIT Tier 1 Manufacturer of steering column, I-shaft and shifter assemblies

produced from metal stampings, roll formed and swedged tubing, welding,

CNC, machined, and injection molded component parts, supplied to Ford,

Nissan, SIA, Mitsubishi, GM, CAMI, Visteon and KOYO.

10/02 to 07/04 Supplier Management & Development Manager

09/01 to 10/02 Quality Manager

09/97 to 09/01 Senior Quality Engineer

. As Program Launch Engineer with MMNA (Mitsubishi) Program received their

highest Quality Award two years in a row 1998 (Ranked Number 1 Supplier)

and in 1999 (Ranked Number 2 Supplier)

. As Quality Manager had 21 direct reports (quality engineers, quality

technicians, quality auditors, quality supervisor)

A.G. Simpson - Earth City, Missouri

JIT Tier 1 Manufacturer of bumper assemblies supplied to GM, Wentzville,

Missouri

12/96 to 09/97 Quality Manager

. Recovered Losses of $1.3 Million from Supplier Reject Returns.

Calvary PCG - Grand Ridge, Florida

12/95 to 12/96 Senior Pastor

Johnson Controls - Shelbyville, Kentucky

JIT Tier 1 Manufacturer of seating assemblies supplied to Ford (KTP-

Kentucky Truck Plant and LAP - Louisville, Kentucky)

7/94 to 11/95 Quality Engineer

. Reduced QRs (Quality Rejects) at KTP from 300 per month to 0, using

problem solving and defect reduction techniques.

Thompson Int'l - Nicholasville, Kentucky

JIT Tier 1 Manufacturer of wheel covers and hubcaps supplied to Ford, GM,

Chrysler, Toyota, Mazda, Diamond Star Motors, Mitsubishi and Nummi.

1988 to 1989 1/90 to 7/94 Quality Engineer

. Reduced waste saving company $48,000 annually.

. Developed and setup complete gage control and calibration system.

Bluegrass Mfg. - Lexington, Kentucky

JIT Tier 1 Supplier of component and assemblies to IBM and General Electric

1989 Quality Manager

. Developed and setup complete Quality Program.

Self-Employed-Logger - Lawrenceburg, Kentucky

1985 to 1988 Logger

. Cut and sold cedar logs to a sawmill in Salvasa, Kentucky

GE (General Electric) Frankfort, Kentucky

Tier 1 supplier to Appliance Park (General Electric) Louisville, Kentucky

1977 to 1985 Quality Lead Inspector and Lab Technician

. 3rd shift lead inspector and lab technician

Highlights of Experience:

Extensive experience in welding (tig, mig, spot, etc), stamping, machining

(CNC, lathe producing gears, shafts splines and other tight tolerance

components), chrome plating, spray painting, powder coating, e-coating,

injection molding, rubber extrusion, casting, and numerous other

manufacturing processes.

. TS16949 / QS-9000 / ISO-9001 / ISO-14001 implementation.

. FMEA; PPAP; APQP; CAR; SCAR; DOE; SPC, TOPS, TQM, MRB, Gage R & R,

Control Plans, Flow Charts, Concept and Design Gages (Check Machines and

Check Fixtures)

. Ford Q-1, WERS, PPAP, 8D

. Chrysler Quality Excellence

. General Motors TFE System, PR&Rs, 5 Phase GP-8; GP11; GP-12

. Taguchi; Kaizen; Lean Manufacturing; 6-Sigma

. Quality department structuring; cost-of-quality; data analysis;

reports/presentations; training; problem resolution; procedures and work

instructions.

. Program Management & Launch Teams - FORD - HSAP (Hermosillo - Mexico).

CAMI, Mitsubishi, Ford, Chrysler, GM, Toyota, Mazda, Diamond Star Motors,

Nummi, Nissan, SIA and KOYO

Education:

Eastern Michigan University

PFMEA January 31 - February 2, 2000 - 2.4 CEU's

Mistake Proofing - February 21 - 22, 2000 - 1.6 CEU's

Project Management - May 2-3, 2000 - 1.6 CEU's

Hopkinsville Community College

Participating in Problem Solving Sessions - Sept. 14, 1999 - .4 CEU's

Managing Change - Sept. 28, 1999 - .4 CEU's

Clarifying Team Roles and Responsibilities - Oct. 27, 1999 - .4 CEU's

Developing Job Skills - November 10, 1999 - .4 CEU's

Other Experience / Training:

General Electric

Blueprint Reading, Quality Control, Computer Training, Injection Molding,

Plastic Materials and their Uses,

CMM (Brown and Sharpe), SPC, GD&T

Thompson Int'l

Synchronous Organization Techniques for Continuous Improvement 40 hrs. -

TOPS 40 hrs. - Managing

Multiple Projects, Objectives and Deadlines 8 hrs. - Time Management

40 hrs. - PPAP 40 hrs. - 8D

Training - Mitutoyo GEOPACK 2000 CMM Training - Computer Training -

Excel, Microsoft Word, Lotus,

WordPerfect, PFS, Gagetrack, SPC1, SQC Pack

Ford Motor Co.

APQP 32 hrs. - WERS 40 hrs.

General Motors (GM)

TFE System, PR&R's, 5 Phase

OMNEX

QS9000 Training - September 1995

ASQC

CQE Refresher Course 24 hrs - 1989 - 1992 - 1994

Integral Solutions Inc.

June 1997 Impact Software Training (Flow Charts, Control Plans, FMEA's)

Brown & Sharpe

Reflex CMM Training - 8 hrs. January 1998

References:

Bob Haley - Quality Manager, Milan, TN - cell 314-***-**** or work (731)

784-4811 ext. 4411

Octavio Vidal - Director Vidal International - 602-***-****

Larry Nissen - Quality Specialist, Hopkinsville, KY - cell 270-***-****

or work 270-***-****

Objective:

Utilize my 30 years of senior quality leadership to work collaboratively,

as part of a global organization, to achieve best-in-class results.

Contact this candidate