Quality Assurance Engineer
Resume:
Allen Caudill
***** ******* **** ***** *****.*******@***.***
St. Clairsville, OH 43950
EDUCATION / TRAINING
B.S. Mathematics (1991) University of Pittsburgh
Pittsburgh, PA
ISO 9000 Auditor Training TSQS
Leechburg, PA
Advanced Process Control Stat-A-Matrix
Princeton, NJ
Six Sigma Black Belt Air Academy
Mt. Pleasant, PA
Lean Manufacturing Respironics
New Kensington, PA
Major Kaizen Practitioner Saint-Gobain
Proctor, WV
PROFESSIONAL EXPERIENCE
CERTAINTEED GYPSUM Proctor, WV
2007 - 2009
Manufacturer of Gypsum Wall Board for the Consumer Goods Industry for
customers such as 84 Lumber and the Manufactured Housing industry for
customers such as Ritz-Craft utilizing calcining, mixing, and extrusion
processes
Quality Manager
Responsibilities:
. Implementation and training of World Class Manufacturing Total Product
Quality Control Pillar steps
. Quality Pillar Champion mentoring Quality Pillar Technicians
. Paper Champion ensuring continued supply of high quality paper
. Product Formulation and specification development and maintenance
. Customer and Sales Liaison ensuring the "Voice of the Customer" is
heard
. UL Program manager ensuring compliance through product and process
audits
. Continuous Improvement Practitioner through performance of Major
Kaizen projects
. Lab Analysis to monitor product and process quality
Achievement: Applied World Class Manufacturing Continuous Improvement
tools to determine and eliminate root cause of "finger cockling" defect and
implement sustaining measures. Result: Decreased customer complaint costs
by approximately $300K per year, internal cull costs by approximately $150K
per year, and eliminated 4% internal yield loss.
NAMSCO PLASTICS INDUSTRIES New Kensington, PA
2002 - 2007
Manufacturer of custom plastic products for the Healthcare industry for
customers such as Respironics, Tyco Healthcare, and Medrad and the Consumer
Electronics industry for customer such as Eaton Electrical and Sony
Electronics utilizing injection molding, liquid silicone molding, sonic
welding, and pad printing processes
Allen Caudill
Page 2
Director of Quality Assurance
Responsibilities:
. Manage QA Department of 3 Technicians & 9 Inspectors
. Implementation & Maintenance of ISO 9001:2000 Program
. Implementation & Maintenance of Sony Green Partner Program
(Environmental Program)
. APQP (Advance Product Quality Planning)
. PPAP (Production Part Approval Process)
. IQ, OQ, PQ (Installation Qualification, Operational Qualification,
Performance Qualification)
. FMEA (Failure Mode and Effects Analysis)
. Root Cause Analysis and Corrective Actions utilizing 8D Problem
Solving methodology
. Implementation of Preventative Actions for Continuous Improvement
. Ensure Vendor Quality
. MSA (Measurement System Analysis) & Calibration Control
. Optimization of Inspection Techniques
. Development & Implementation of Quality Inspection Plans
. UL Program manager ensuring compliance through product and process
audits
Achievement: Developed & Implemented all procedures, training, and
documentation necessary to develop a Quality Management System. Result:
Obtained ISO 9001:2000 Certification within six months of mandate which
allowed us to retain certain major customers and attain new ones as well.
SONY ELECTRONICS, INC. Mt. Pleasant, PA
1999 - 2001
Manufacturer of Consumer Electronics components for customers such as Dell
Computer utilizing the Photo-Chemical Etching process
New Product Development Engineer
Responsibilities:
. Research & Development
. New Product & Tooling Design
. Integration of Proto-types into Production
. Field Testing at other Sony facilities both domestically and
internationally
. Ensure New Product Quality both In-House & at Customer
. SPC (Statistical Process Control) utilizing SPC KISS and Minitab
. DOE (Design of Experiments)
. MSA (Measurement System Analysis)
. Regression Analysis
. Reduce COPQ (Cost of Poor Quality)
Achievement: Developed new "offset" style extra slit to minimize
"bridging" problems in-house and minimize RPI issues at customer's
facility. Result: After implementation of new "offset" style extra slit,
in-house bridging was reduced from about 4% to under 1% for a savings of
approximately $1.5M per year, and RPI at the customer's facility was
eliminated allowing us to achieve an additional $3M in new sales.
Allen Caudill
Page 3
LEADING TECHNOLOGIES, INC Leechburg, PA
1994 - 1999
Manufacturer of Lead Frames for the semiconductor industry for customers
such as Motorola and Rockwell utilizing Photo-Chemical Etching, Metal
Stamping, and Plating processes
Quality Assurance Engineer / Etch Process Engineer
Responsibilities:
. SPC (Statistical Process Control) utilizing SQCpack
. Process Optimization & Defect Reduction
. Root Cause Analysis and Corrective Actions utilizing 8D Problem
Solving methodology
. Ensure Vendor Quality
. MSA (Measurement System Analysis) & Calibration Control
. Optimization of Inspection Techniques
. Inspection Documentation Control
. Internal & External ISO Auditing
. Development of Process Specifications
. Documentation of Operating Procedures
. Personnel Training
. Preventative Maintenance
. New Product Development
. Database Development & Maintenance
Achievement: Calculated control limits and applied statistical process
control to "out of control" lead down set process. Result: Within two
months of implementation, yield increased by approximately 30%, saving
approximately $200K per month
Achievement: Analyzed etch related defect incorrectly diagnosed as "mouse
bite" and correctly identified the source of the defect to be premature
"lifting" of the photo resist in the latter stages of etching. Result:
Implemented the appropriate corrective actions to eliminate "lifting"
saving approximately $200K per month.
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