Quality Assurance Manager

TED JOHNSON

Temecula, CA ***** *******.****@*****.*** 951-***-****

QUALITY ASSURANCE/MANUFACTURING MANAGEMENT

Quality professional with over 20 years experience in diverse industries.

Excel at using leadership and interpersonal skills to build cohesive,

conscientious teams that develop and implement state of the art quality

management systems. Consistently delivers product that conforms to quality

processes while exceeding customer expectations in quality and reliability.

Results include dramatic reduction in defects, higher levels of customer

satisfaction and increased profitability.

ISO 9001/TL 9000/QS 9000/TS Document Control Dimensional Analysis

16949

RAB Lead Auditor Supplier Management Customer Relations

Lean Six Sigma - Black Belt Error Proofing Department Planning

Continuous Improvement Environmental Testing Scheduling/Budgeting

PROFESSIONAL EXPERIENCE

DENSO WIRELESS SYSTEMS AMERICA (DWAM), Vista CA 1998 - 2010

Wireless handset, automotive electronic control units and OE navigation

systems.

Director of Executive Office 2009 - 2010

Director, Quality Assurance - OE Navigation Systems and Automotive

Electronics 2001 - 2009

Sr. Manager, Quality Assurance Wireless Handsets and Automotive Wireless

Units 2000 - 2001

Manager, Quality Assurance - Wireless Handsets Start-up 1998 - 2000

Director of Executive Office 2009 - 2010

Selected to lead companywide systems improvements and standardization of

DENSO Wireless operations with the goal of exceeding the performance level

of global DENSO companies.

. Implemented DENSO standardization program previously delayed by three

years moving the project ahead of schedule, contributing to DENSO Japan

decision to retain DWAM operations in Vista, CA.

. Drove company-wide cost reduction and lean activities implementation

resulting in an overall savings over $100K in FY 2009.

. Completed space reorganization project opening more than 3K sq. ft. of

space opening the way to a second profit center for the company.

Director, Quality Assurance - OE Navigation Systems and Automotive

Electronics 2001 - 2009

Overall responsibility for quality of products manufactured and shipped

from DWAM.

. Improved internal GM warranty analysis process through early detection

and resolution to become "Best in Class" for GM navigation products.

. Initiated a supply chain management program with the Tier II supplier and

design to drive improvements, reducing customer defects moving DENSO from

ineligible to eligible status on the GM bid list.

. Analyzed and modified test process, contributing to an 86% customer

defect reduction over three years.

. Established an in process defects analysis team focusing on process

improvement and error proofing resulting in an 88% reduction in defects

exceeding company targets.

. Introduced testing system at vehicle assembly plants allowing resident

engineers to screen product prior to return, resulting in an 80%

reduction in No Trouble Found returns.

TED JOHNSON *******.****@*****.*** Page Two

. Successfully led multiple third party registrations from TL9000 to QS

9000 and TS 16949 as well as Ford Q1 to meet the changing business

requirements.

. Re-established the QA department after a 90% reduction in force (from 59

to six employees) when business changed from wireless handsets to

automotive navigation systems.

. Integrated the transition from high volume consumer electronics wireless

handsets (for Sprint) to automotive requirements within a three month

lead time requiring process development and associate retraining meeting

requirements for key customer (Toyota.)

Sr. Manager, Quality Assurance - Wireless Handsets and Automotive

Navigation Systems 2000 - 2001

Responsibilities include Design quality, supplier qualification, technical

service, customer quality, quality engineering, handset recovery and

receiving inspection (59 associates).

. Developed a design quality department to focus on new product

introduction and supplier qualification reducing qualification time and

decreasing production defects.

. Implemented a product qualification procedure including multiple

companies, DENSO Japan, LA Labs (Design) and DENSO Wireless reducing

design and production defects.

. Successful third party registration of ISO 9001 and TL9000.

Manager, Quality Assurance - Wireless Handsets Start-up 1998 - 2000

First DENSO wireless product overseas manufacturing facility.

New business start-up activities including QA staff requiting, equipment

acquisition, procedure development, associate training and design

qualification while achieving an on time launch and customer delivery.

DENSO SALES CALIFORNIA (DSCA), Long Beach, CA 1980 - 1998

Automotive and industrial air conditioning manufacturing, automotive

aftermarket kit and component sales/ distribution.

Manager, Quality Assurance 1995 - 1998

. Initiated a quality assurance department responsible for product

qualification, supplier qualification and development and customer

quality.

. Successful third party registration of ISO 9001 and QS 9000.

Asst. Manager, Quality Control - Automotive Air Conditioning Tube and Hose

Manufacturing. 1990 - 1995

ADDITIONAL RELEVANT EXPERIENCE

Calibration and gage R&R Reliability testing Supplier control

Dimensional analysis (CMM) Associate training Non destructive testing

EDUCATION AND TRAINING

Business and Quality Engineering, statistics, reliability testing and

quality assurance

Lean Six Sigma - Certified Black Belt

QS9000 ANSI - RAB Accredited Lead Auditor

ISO 9001, TL 9000, TS 16949 Certified Internal Auditor

Advanced Quality Planning, Production Part Approval Process, Failure Mode

Effects Analysis, and Measurement Systems Analysis

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