Quality Manager

John Wiley

*** ****** **. - *******, ******** ***68 - Phone: 816-***-****

QUALITY and OPERATIONS

Hands-on, data driven Senior Manager with strong experience leading

turnaround initiatives, plant start-ups, quality system implementation and

Third Party Registrations. Skilled in identifying opportunities and

implementing plans which achieve organizational goals and exceed Customer

expectations. Specific expertise in:

Total Quality Management Poka

Yoke ISO 9000 series

Lean / 6S

Problem Solving/Root Cause QS-9000

Internal Auditing

Kaizen TS 16949

Design for Assembly

Gauge R & R AS9100

Supply Chain Management PFMEA

FAA requirements

Nadcap

GKN, St. Louis, Missouri

2008 - Current

Aerospace composites and metals manufacturer

Quality Specialist III

. Lead Auditor for Nadcap, Product, Process, Surveillance audits and

Customer Product/Process assessments.

. Perform OV assessments, verify corrective action implementation and

work with operations to promote continuous improvement.

Polytainers Inc, Lee's Summit, Missouri

2006

- 2008

Injected molded plastic containers for dairy products

Quality Manager

. Reduced inspection documentation time 15% by replacing hard copy

method with database and computer distribution.

. Eliminated 4 to 8 hours of OT per week through additional training

and re-alignment of test responsibilities.

. Used Gauge R & R analysis to identify data flaws. Used SPC to

identify process variation.

B/E Aerospace, Lenexa, Kansas

2002 - 2005

Supplier of oxygen and galley products to the Aerospace industry and FAA

Certified Repair Station

Quality responsibility for Machine Shop, Fab Shop, Assembly and Repair

Station.

Quality Manager

. Wrote Quality Manual, Level II procedures and Level III Work

Instructions needed to document Quality Management System, achieve

ISO/AS9100 Third Party Registration (Feb 2005) and maintain Customer

and FAA compliance. Quality Manual recognized by Third Party

Registrar as "Best Practice".

. Facilitated Lean initiative to improve efficiencies and developed AQL,

Corrective Action and NCR databases to go paperless. Recognized by

Third Party Registrar as "Best Practice".

. Determined KPI's and implemented continuous improvement initiatives to

achieve Boeing's D1 to D6 transition.

. Improved new product certification success 75% by implementing FAI

process. Included providing Test personnel and DMIR training, test

protocol improvements and coordination of Reliability Lab, Test and

DMIR activity.

. Worked with Engineering and Process Engineers to develop assembly

fixtures, determine critical sequence and in-process inspection

(initiated PFMEA and Control Plans). Reduced first time test failures

by 88%.

. As Lead Auditor, identified areas of non compliance and led corrective

action efforts. Taught internal auditing to support staff.

. Partnered with suppliers to clarify expectations and improve test

capabilities. Developed and implemented methods to monitor and rate

supplier performance.

Productivity Improvement Centre, Oshawa, Ontario Canada

2001 - 2002

Provider of Quality Services

Consultant

. Prevented defects from reaching Customer by providing Third Party

containment and process verification at supplier facility.

. Readied facility for TS 16949 Registration. Provided detail gap

analysis to show areas of risk, determined variance from established

corporate procedures and directed improvement. Wrote Quality

Management System procedures. Trained hourly and staff to procedures.

Lear Corporation, Liberty, Missouri

1999 - 2000

Tier-one seat complete supplier to Ford Motor Co.

Operations Manager (1 year)

Retained to ensure smooth transition of contract from Johnson Controls to

Lear. Required maintaining delivery and quality ratings and achieving

Third Party Registration.

. Provided management to Production Staff of 225 Union employees to

ensure production demands were met to achieve 100% in-sequence

delivery.

. Reduced manning by 30% and improved efficiencies through Kaizen events

for line balancing and variation reduction.

. Improved First Run Capability by 40% through problem identification,

pushing problem up stream and problem resolution (8D, Poka Yoke,

Kaizen).

. Ensured success of new program launch by utilizing APQP and PPAP

tools.

. Developed method to monitor production output against "pull" to ensure

meeting delivery requirements.

. Facilitated efforts to achieve ISO/QS-9000 Third Party Registration

(May 2000).

Quality Manager (6 months)

. Lead efforts to achieve site approval by meeting Customer's Supplier

Quality and QOS requirements.

. Led Kaizen, Poka Yoke and Design for Assembly activities to prevent

escapes and maintain <100 PPM quality target.

Johnson Controls, Liberty, Missouri

1994 - 1999

Tier-one seat complete supplier to Ford Motor Co.

Quality Manager

Recruited to attain Site approval and resolve the quality issues that

resulted from a problem filled plant start-up. Objectives must be met

within one year.

. Developed and implemented Supplier Quality and QOS compliant Quality

System attaining Q1 in 6 months. Received Johnson Controls' Chairman

Award for receipt of the highest score ever earned by an Automotive

System Group plant.

. Drove problem resolution efforts to attain 100PPM status. Received

Ford's Supplier of the Month award for problem resolution efforts.

Incorporated APQP, PPAP and MSA into Quality System. Implemented SPC

and Gauge R & R initiatives. Used Kaizen (certified trainer), Poka

Yoke and Design for Assembly activities to prevent defect occurrence

and led Lean initiatives to eliminate waste. Received Johnson

Controls' Merit Award for exceeding Customer expectations.

. Facilitated efforts to achieve ISO/QS-9000 Third Party Registration

(Apr 1996). First facility in Ford platform to attain certification.

. As lead auditor, identified areas of non compliance and led corrective

action efforts. Taught internal auditing to support staff.

. Met with Customer to resolve issues, wrote Control Plans and PFMEAs,

provided training, internal auditing and direction to sister plants

where they had failed to get Control Plans and PFMEAs accepted,

problems resolved or attain ISO/QS certification. Looked to as

benchmark plant and product/Quality System authority.

. Assisted start-up of cut & sew plant located in Mexico.

S&H Fabricating, Maquoketa, Iowa

1993 - 1994

Tier-one HVAC supplier to General Motors

Quality Manager

Manage quality activities for the facility. Assure Customer receives

quality product. Acts as Customer contact. Works with Customer to resolve

problems.

. Developed formal Quality Management System (provided direction and

training).

. Implemented method to determine process output (used go/no-go gauges).

Taught gauge measurement and defect analysis.

. Resolved quality problems by partnering with Customer to establish

lines of communication and identify needs. Company's name removed

from Wall of Shame and put on Wall of Fame.

Integram/Atoflex, Pacific, Missouri

1989 - 1992

Tier-one seat complete supplier to Chrysler

Quality Director (2 years)

Given additional responsibilities for foam facility. Required to bring

foam and assembly facilities under one Quality System.

. Developed and implemented Level II procedures. Led efforts to provide

Quality System training for Management, Operators and Quality.

. Led initiative for supplier adherence to PSO requirements. Worked

with trim supplier to improve cut & sew processes reducing first time

through failures by 30%. First soft trim supplier to receive Chrysler

Self-Certified status.

. Led process and supplier improvement efforts. Partnered with Customer

to resolve quality issues. Received Chrysler's Quality Excellence

Award for maintaining quality rating of less than 200 PPM (1990 and

1991).

Quality Manager (1 year)

Responsible for assembly plant launch and follow-up site approval.

. Wrote Quality Plan, Level II Procedures and provided training for

Management, Production and Quality needed to implement SQA compliant

Quality System.

. Quality rating negatively affected by poor quality of purchased

product. Designed and implemented Supplier Management Program which

included facility surveys, production sign-off and rating system.

Reduced receiving inspection by 80%.

Tri-Con, Columbia, Missouri

1985 - 1989

Tier-one seat complete supplier to Chrysler

Quality Manager

Success dependent on getting facility removed from Customer's "Drop Source"

list and resolution of poor relations between Customer and plant.

. Developed and implemented quality plan which met SQA requirements.

. Resolved poor relations by partnering with Customer to establish lines

of communication. Developed acceptance standards, determined

ownership and educated Customer (attained 100% quality rating based on

9 consecutive months of zero defect).

. Led corrective and preventive actions to help eliminate recurring non-

conformances.

. Used Kaizen and Poka Yoke to eliminate build issues.

. Assisted start-up of cut & sew plant located in Mexico and stamping

plant located in Nebraska.

EDUCATION

Kansas State University Manhattan, Kansas

Bachelor of Architecture

CONTINUED EDUCATION

Measure, Monitor and Improve Supplier Performance - MGI

Supply Base Management - Saddle Mountain Institute (.70 CEU)

Quality Management - BBP

Quality Communication - AAIM (1.00 CEU)

Positive Employee Relations - AAIM (.80 CEU)

Basics of Effective & Consistent Supervision (.60 CEU)

Statistical Process Control - St Louis Community College (1.40 CEU)

SPC - Iowa Community College (42 hours)

Train the Trainer - St. Louis Community College (1.00 CEU)

Internal Auditing for QS-9000 (1.00 CEU)

Internal Auditing ISO 9001:2000 (1.65 CEU)

PPAP - General Physics Corporation (.35 CEU)

APQP - General Physics Corporation (.35 CEU)

5S and Visual Management - Johnson Controls

Quick Problem Solving - Johnson Controls

Global 8D - Ford Motor Company (.50 CEU)

PIP/EPM (Launch Management) - Certified Instructor

Kaizen - Certified Trainer

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