Manager Quality Assurance
Resume:
ANTHONY A. PIPCZYNSKI
*** ****** **** - ******, ** 06019
860-***-**** (home), 860-***-**** (cell), ****@*******.***
Results driven executive with expertise in multi-site, multi-shift
operations management. On-going cost reduction through metrics development
for first-time yields, scrap/rework/return reduction and on-time delivery
improvement. Builds, coaches, and leads high performance teams, for high
efficient cost-effective results, and employee job satisfaction.
Particular experiences include:
* Managed P/L, assembly, design and manufacturing engineering, automation
design, production, materials, planning, quality, human resources,
payables, building security, safety, environmental, and facility/machine
maintenance
* Led Design to Cost initiatives on highly engineered precision products.
Defined production ramp-up, capital, manpower and space requirements, cost
reductions through process improvements and feedback to design engineering
* Led design and lean manufacturing teams to ensure robust equipment and
processes for new business development, company growth, efficient release
of product to production, and delivery of all technical documentation
* Generated plans and procedures for quality, new products, ramp up and on-
time delivery
* Designed and implemented ISO/QS 9000, Medical Device and other Quality
programs including Management Representative and FDA correspondent and
Regulatory UL and CE Mark
* Managed failure analysis, root cause, and corrective action reporting,
for highly engineered products
* Participated in Merger and Acquisition due diligence, integrated
personnel, polices and procedures to existing culture
* Significant experience and prime contact for domestic and international
government contracts, held Secret Clearance.
* Developed reliability programs and specifications: FMEAs, qualification
testing protocols (mechanical and temperature shock, humidity, vibration,
burn-in, life testing), feedback for design, tooling and process
improvements
* Well-versed in SPC, JIT, TQM continuous improvement, Lean, Kaizen, and
work redesign
* Certified to Category C (Workmanship/ Soldering Instructor) of MIL-STD-
2000/IPC
* ASQ Certified Quality Auditor (CQA). Certified (forty-hour) ISO 9000 Lead
Assessor. Secret Government clearance
* Working knowledge of automotive, aerospace, medical, semiconductor, FDA,
and military/industrial specifications
* Ongoing participation/ certification in technical seminars in Operations,
Quality, Engineering, Manufacturing and HR
* Participated in intensive 18 month company coaching program
M.B.A., (Operations/Finance), American International College, Springfield,
MA
M.S., Organizational Development, American International College,
Springfield, MA
B.B.A., Management/Technology, American International College, Springfield,
MA
A.S., Electronics, Springfield Technical Community College, Springfield, MA
B.S.E.E. (half completed), Western New England College, Springfield, MA
___________________________________ PROFESSIONAL EXPERIENCE
________________________________
ISO-New England, Holyoke, MA 2008 - present
An energy Independent Service Organization operating the electrical grid
and energy markets for the New England States.
Quality Programs Manager
. Management Representative, overall management of the Quality System and
OSHA Compliance.
. Corporate Risk Management, evaluate compliance and risk level and
schedule resolution with Program Managers.
Farrel Corporation, Ansonia, CT 2004 - 2008
An $80mm Global manufacturer of new and refurbished industrial capital
equipment machines and spare parts.
Director, Manufacturing
* P/L responsibility for 2-plants, 2-shifts: manufacturing, rebuild product
engineering, production control, shipping, receiving, quality,
environmental, maintenance, safety, employee relations, union
negotiations, buildings, security
* Participate in quotes, order reviews and set the manufacturing location
and delivery dates for global customers
* Negotiated 3 year Union Contract (new pay scales, cross-training,
reassignment during peak workloads)
* In conjunction with Purchasing, developed global procurement and supply
chain management plan
* Developed and implemented building, facility and machinery upgrades
_____________________________ PROFESSIONAL EXPERIENCE (Continued)
____________________________
Outokumpu Advanced Superconductors, Waterbury, CT 2002 - 2004
A $30mm manufacturer of MRI superconductor wire from chemical clean and
extrusion through fine wire completion.
Manager, Operations
* P/L responsibility for 3 shifts: assembly, production, manufacturing
engineering, materials, procurement, payables, production control,
shipping, receiving, quality, environmental, maintenance, safety, and
building security
* Developed PM and machine maintenance program and upgrades, negotiated
with machine manufacturers
* Program management for the installation of $1mm automated wire drawing
machine
* Researched relocating the entire facility to meet new product production
ramp up and suitability needs
* Daily involvement in material review board, internal audits, corrective
action, and design release/changes
* Prime employee relations management interface to the bargaining unit
(United Steelworkers)
The J. M. Ney Company, Bloomfield, CT 1995 - 2002
A $40mm manufacturer of precious metal aerospace, automotive and medical
stamping, electronic sensor insert molding, probe cards, specialty
contacts, dental alloy, precision screw machine dental copings/screws, and
catheter probe tips.
Director, Quality Assurance/HR
* Led process development including tooling optimization for inline strip
welding, sorting bowls, progressive dies, precision multi-cavity molding
tooling, vision systems and automation process control
* Designed Six Sigma, Lean, TQM, Continuous Improvement, SPC, PPM
reporting, root cause analysis/corrective action
* Consolidated suppliers for effective performance monitoring and involved
in strategic outsourcing decisions
* Management representative for ISO/QS quality certifications, MDD, UL and
FDA correspondent
* Managed all HR programs including coaching, mentoring, training,
succession and retention plans
K and M Electronics, West Springfield, MA 1987 - 1995
A $30mm multi-site manufacturer of high voltage power supplies for military
night vision and missile equipment, precision channel electron multipliers,
wireless infrared, electronic components, hybrid circuits, and molded
connectors/cables.
Director, Quality Assurance/HR 1993 - 1995
* Managed quality, reliability, failure analysis, security, facility
maintenance, safety and HR
* Management representative for ISO 9001 corporate-wide (three facilities)
Manager, Semiconductor Manufacturing/Quality 1987 - 1993
* P/L responsibility for a corporate division: 2 shifts, design and process
engineering, production, materials, shipping, quality, capital equipment,
Failure & Reliability Analysis, floor space requirements for production
ramp ups.
* Converted manufacturing to automation through the use of automated pick &
place machines and soldering equipment
* Designed a comprehensive workmanship training & SPC program for hourly
personnel
* Created work cells for high quality at improved rates, eliminated
inspection, and created ship to line deliveries
Kollmorgen Corporation, Electro-Optical Division, Northampton, MA and
Keene, NH 1973 - 1987
Over $100mm US/International OEM of submarine/tank periscopes, infrared
missile sensors, aerospace borescopes.
Manager, Quality Assurance, Keene, NH 1986 - 1987
* Implemented/managed quality, reliability, staffing for infrared missile
sensors for defense contractors
Manager, Quality Engineering/Electro-optical technician/Various positions,
Northampton, MA 1973 - 1986
* Managed quality for electronic, optical, camera, RF, mechanical, computer
systems, schedules, budgets, and staffing
* Designed equipment for testing of periscopes and borescopes for electro-
optical-mechanical systems and subsystems
* Started as Production Technician, promoted to Quality Technician, Quality
Engineer and then to Quality Manager
Alarm Engineering
Electronic Technician - Assembled, tested and repaired ultrasonic burglar
alarms part time while earning college degree
____________________________________ SELECTED ACHIEVEMENTS
_________________________________
Increased monthly quantity of wire shipped by 100% with no increase in
people or equipment.
Result: Produced an annual savings over $1.5 million and significant
improvement on on-time delivery
Reduced manufacturing lead time from 20 weeks to 10 weeks and increased on-
time delivery from 70% to >95%
Result: Reduced WIP inventory dollars by $2 million and significant
improvement in out going quality.
Implemented "Best Practice" initiative in all processes.
Result: Reduced wire breaks from an average of 50 to an average of 5
breaks per billet, saving $750,000 on the contract and significant
improvement plant production performance.
Instituted alternative recruiting methods resulting in reduction of hiring
costs by 67%. Identified and eliminated employee relations issues that
were contributing to high turnover.
Result: Produced annual savings of $400-500,000.
Upon hire, led the process of securing IS09001 certification. Reorganized
staff and procedures, gained trust of participants to ensure seamless
cooperation to achieve objective within short time frame.
Result: Eliminated major deviations with potential lost revenue of $2
million for the corporation.
Led project to upgrade main computer system. Outlined project, organized
team efforts, and achieved conversion within time constraints and without
the need for outside consultants.
Result: Savings of $100-150,000.
Designed and implemented six-sigma program for major automotive customers
including internal operator training, metric development and presentation
to customer representatives.
Result: Incorporated into existing procedures with no added staff,
obtained "ship to line" status on Cpk/Cp data.
Designed and implemented operator certification training program.
Result: Saved $300-500,000 in recruiting costs and productivity gains
annually by reducing first-year turnover by 90%.
Reduced work-in process from $2 million to $100,000, through implementation
of lean manufacturing techniques and training. Eliminated seventy
inspection and troubleshooting positions and reallocated new-found floor
space to production.
Result: Created cost savings of $5 million.
Eliminated bottlenecks and two supervisor positions while improving
throughput, employee morale, and teamwork by addressing technical and
equipment issues and introducing training initiatives.
Result: Division performance increased by 50% and many hourly positions
were reassigned to another division.
Negotiated, planned, and managed complex move of two production facilities
into a new 150,000 square foot building with no production downtime.
Organized task into series of milestones, negotiated cost savings with
movers, riggers, and equipment manufacturers, established schedules and
time lines to coordinate activities to achieve desired efficiencies.
Result: Savings of $200-300,000.
Reduced machine assembly time by 10% on average through the implementation
of pre-assembly of major components.
Result: Averted the hire of additional labor at $50,000 - $100,000 per
year and reduced lead time by1 - 3 weeks.
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