Engineer Quality Assurance
Resume:
Frank Macco
Clarkston, MI *8346
Phone 248-***-****
Mobile 248-***-****
*******@*******.***
The last 10 years working as an Independent contractor under the name Northview Consulting.
Manufacturing Quality Systems and project specific issues (problem resolution) for various companies
both domestic and international. (Canada, China, Mexico, Taiwan, Europe). Including improving the
dispatch time for Emergency Medical Service for the State of Michigan. Management/supervisor
experience includes supervising skilled trades and production lines. Conducting assessments for
procurement qualifying for new sources, auditing systems, and corrective actions on product lines
from complex electro-mechanical hardware through distribution centers, from plastics to armored
forging. Implementing Mill-Standards and ISO/QS-9000 systems and ISO 14000. Conducting
workshops and training seminars at suppliers facilities. Process changes resulting in cost savings and
product quality improvements. Extensive tooling and machining background allows me to work in a
wide range of processes and product lines. As a Quality Engineer writing control plans, flow charts,
FMEA’s, layout reports, verify and submit required SPC data, and assuring customer required testing
is conducted per specifications and PPAP’s are submitted to the Auto Companies and sub-tier
suppliers on time. Participate in APQP meetings to interpret GD&T symbols and suggest the most cost
effective and value added inspection equipment to verify dimensional control is maintained.
OBJECTIVE
Supplier Quality Engineer
EXPERIENCE
Northview Consulting Independent Contractor Jan. 1999 to Present
Stanadyne Corporation Windsor, CT Jun. 2009 – May 2010
Assignment Develop approved suppliers in China and India producing components for fuel
distribution system. Machining, heat treating, assembly operations. Develop routing process, with
inspection check points. Manufacturing method including tool set up and tool change cycle. Review
PPAP documentation and ISIR samples.
VSC (Verify) Stratford CT. (Sikorsky). March.
2009 to May. 2009
Monitor supplier production out put to meet scheduled time line.
Process Development Corporation, Livonia, Mi. May. 2008-October. 2008
Contract assignment, bring foundry back on schedule after a fire. On site in Europe coordinating a
24/7 foundry production line including core line and scheduled maintenance to support the assembly
line requirements launching several new platforms. Assignment completed in 5 months fill pipe line,
build inventory, create a schedule with open capacity to meet unscheduled customer requirements.
Chrysler LLC. Auburn Hills, Mi Jan. 2005-Jan. 2008
Contract position, Quality Assurance Audit Team Working with team of 40 people. Created,
developed and proved out new tools to assess supplier systems and provide onsite assistance
implementing solutions to resolve problems and prevent new problems. Employing this new
approach, our success rate reducing defective product from selected suppliers (90) averaged 62%.
Conducting workshop teaching the methods developed building a win/win environment with
suppliers.
Continental, Auburn Hills, Mi March 2004-Jan.2005
Contract Position working on supplier development programs on-site in Mexico, China and the US.
Products include Plastic products in Mexico to Ductile Iron production in China. Introduce, train, and
develop suppliers
in AIAG requirements for submitting PPAP’s and associated documents. Training on problem
resolution 8-D discipline applied at suppliers. Working on site with suppliers to improve quality
products and procedures.
Troy Design, Lansing, MI May, 2003-March, 2004
Contract Position at ASC for General Motors (SSR) Project in supplier development conducting
Audits at suppliers and training on General Motors GP-5, GP-9, GP-12, and PPAP’s procedures,
assessing supplier performance. Corrective action reviews and suggestions for improvements to
manufacturing and quality system. Develop supplier continuous
Improvement process meets customer requirement of higher quality and lower cost. This is a high
end, low volume
Vehicle with special requirements for a high production supplier base.
Newcor-Deco, Inc., Royal Oak, MI Mar.-2000-Oct. 2002
Contract Position Supervisor: Responsible for Machining, Inspection & Assembly of Turbo-Chargers
for Truck and Auto Industry. Procuring tooling for machining cast iron, powdered metals and
aluminum. CNC lathes, machining centers, cleaning stations, assembly and testing.
Quality Engineer: Responsible for PAPP and associated documentation. Dimensional Lay Out
reports to Numbered Print, writing control plans, flow charts, FMEA’s, submitting SPC Data to
customer, Gage R&R. Interpret GD&T and plan Inspection processing and Gauging. Consult with
engineers and other team members to Poke-Yoke the system using
Proximity switches, lights, solid stops to prevent defects.
Customer contact for corrective action, investigating root cause, initiate containment plan.
Benchmark Corporation 1999-2000
Contract Position at Key Plastics, Inc. in Plymouth, MI. Coordinated the GM-GP5 and GP-12
Containment Process of Controlled Shipping at Levels 1 and 2, supervising and directing off-site and
on-site
Disciplines made up of internal employees and out source inspection concerns. Present daily
progress report to plant management and customer. Recommend corrective action to manufacturing
team.
MASCOTECH FORMING TECHNOLOGIES, INC., Livonia, MI 1998-1999
QS-9000 Management Representative,
Quality Engineer: Customer contact for PPAP and corrective action. Write, edit, and review QS-
procedures. Schedule and review internal audit findings suggest changes to management to meet
business plan goals.
FEDERAL SCREW WORKS, Romulus, MI 1993-1998
Quality Engineer: Responsible for PAPP and associated documentation, writing, FMEA’s, Control
Plans, Flow Charts, including customer required Torque test, and Key Character S.P.C.
documentation meets 1.67 CPK. Review metallurgist reports on both raw material and heat-treated,
coated and uncoated product. Including tensile and x-ray hardness test both Rockwell and Brinell.
Interpret GD&T and acquire required Inspection Gauging equipment. Interface with customers to
develop robust product and resolve problems.
GENERAL DYNAMICS LAND SYSTEMS, Sterling Heights, MI 1984-1993
Supplier Quality Assurance Representative: National and international responsibilities with extensive
supplier contact. Develop supplier adherence to contract requirements. Conduct workshops,
training programs, review corrective action responses to assure problem resolutions. Conduct
material analysis on a wide range of products from armor steel and aluminum to bullet proof plastics
and rubber components. Managed a diverse group of suppliers of commodities ranging from
standard hardware to complex electro-mechanical, hydraulic, pneumatic interfaces. Suppliers were
introduced and certified to statistical techniques under my management.
NORBERT INDUSTRIES, Sterling Heights, MI 1981-1984
Chief Inspector: Reviewed manufacturing and production process, approving first piece. Prepared
inspection reports and
certification per customer requirements. Approved tooling required for production.
ATHENS MACHINE CO., Detroit, MI 1979-1981
As co-owner of machine tool rebuild company, responsible for generating sales, engineering and
finance.
BABCOCK & WILCOX, Rochester, MI 1967-1979
Division QC Liaison Automated Machine Tool Division – coordinated a multi-plant operation,
Troubleshooting between engineering, suppliers and assembly.
Plant QA Manager over department of Tool and Layout Inspectors; inspecting precision components
for metal removal Machines, Tooling, and customer try out parts.
MILITARY U.S. Army – Honorable Discharge, 1962-1965
EDUCATION: Home schooled on our farm in Michigan
Received GED from U.S. Army in September 1962
QS 9000 Internal Auditor Perry Johnson
Dale Carnegie Course
Certified Weld Inspector
Statistical Process Control Seminars/Workshops
Inspection Management, Michigan State University
Supervisor Management, University of Toledo
Journeyman Tool and Layout Inspector (AA) UAW
Hydraulics, Oakland University
Certified McBeth Light test for color discrimination
Authored Article published in AIAG Action Line Magazine
titled (Short Term Thinking-Long Term Pain)
References:
John Casey Chrysler Director 248-***-****
Jim Lenhardt Chrysler Manager 248-***-****
Ken Simpson Chrysler Leader 248-***-****
Kurt Vogler Chrysler Manager 248-***-****
Gary Elrod Ford STA Engineer 248-***-****
Eileen Worden Michigan Medical Director 517-***-****
Dave Hartz Stanadyne Manager 860-***-****
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