Quality Manager
Resume:
Dennis R. Leyes
South Bend, IN, 46614
Email: ********@*******.***
Linkedin http://www.linkedin.com/in/dleyes
Professional Summary
Senior Quality Professional with expertise in design, implementation,
maintenance, and third party certification of Quality and Lean / Six
Sigma Manufacturing Systems serving the automotive, motorsport,
appliance, and consumer products industry. I have proven results
through all levels of production and delivery, including customer
service, while serving in diverse manufacturing facilities. I am an
energetic, organized, and focused leader who successfully has earned
the respect of all layers of management and hourly personnel. I am a
technically competent problem solver driven by permanent corrective
action and continuous improvement while focusing on problem
resolution, prevention and cost reduction.
Technical Skills
Lean Manufacturing / Six Sigma - Green Belt Trained
Kaizen 8D / 5 WHY Problem Solving
MS Office
MS VISIO (Visual Communications Software)
DMAIC Process
ABC Flowcharter (Advanced Product & Process Flow Charting Software)
AQUA (Advanced Quality Assurance Software)
APQP
ISO9001: 2000 Registration / Certification
TS16949:2002 Registration / Certification
Cost of Quality
Lessons Learned Incorporation
Project Management
Staffing, Development, Training, & Team Building
Mistake Proofing
Process & Product Auditing
Document Control System Development, Incorporation, & Maintenance
Internal / External Corrective & Preventive Action System
Visual Work Systems / Standards
Budgeting
Hiring and Firing
ISO / TS Management Representative
Pareto Analysis
Statistical Process Control (SPC)
Experience
Universal Manufacturer of needle rollers used in 08/04 - 09/08
Bearing LLC., automatic transmissions, universal
Bremen, IN joints, front wheel drive constant
velocity joints, water pump bearings,
roller clutches, cam lifters, rocker
arms, cam rollers, starter drives, and
as pins & dowels for various
applications.
Quality Technician (Engineer)
Amended Quality Management System to meet requirements of TS16949:2002
which led to successful certification / registration in fourth quarter
2005 through QMI
Designed 19 processes with measureables involving 20 individuals in
18 months
Administered ISO9001:2000, QS9000, & ISO14001 document control system
consisting of over 400 documents to meet requirements of governing
quality standards and UB LLC. Quality Management System (QMS)
Implemented and maintained existing documentation necessary for
scheduled Quality Management System (QMS) & Environmental ISO 14001
system audits. Ensured internal audits were distributed and 100%
completed per schedule, monitored corrective action that were issued,
taken, and completed within the timelines established resulting in
process improvement.
Maintained and improved corrective action system and corresponding
customer responses in either 8D or 5 WHY format in conjunction with
Quality Manager resulting in 40% reduction in customer complaints FYTD
2008
Developed /originated documentation which strengthened & supported
corrective action teams / process resulting in 100% integration of
updates to Policies, Process Maps, Procedures, Work Instructions, and
Forms
Participated in and led Team Problem Solving activity assigned by
Management
Participated in and led Quality Improvement projects assigned by
Management.
Included 100% application of Lessons Learned to all associated
processes
TOEFCO Engineered 12/99 - 03/04
Coating Systems, Company is a Licensed DuPont
INC., Niles, MI applicator of Teflon , Tefzel and
Haylar , coatings in both powder
and liquid form to assorted metal
substrates
Quality Manager
Managed Quality Management System (QMS) within the Niles plant to meet
governing requirements of ISO9001: 2000 standard.
Amended / developed Quality Management System (QMS) to meet the
requirements of ISO9001: 2000 standard and led company to successful
second quarter 2003 certification through NSF .
Developed comprehensive PPAP program to meet requirements of TRW,
TENNECO Automotive, Faurecia, & Federal Mogul
Resulted in obtaining increased sales volume of $800 M in 2003 - 2004
Refined auditing system, Corrective / Preventative Action program, and
8D reporting to improve Quality Management System (QMS)
Implemented & refined Continuous Improvement Process with project time
lines, resource allocation payback and subsequent documentation
resulting in justification for $300M expenditure in mistake proof
coating fixtures
Walker 03/99 - 12/99
Manufacturing Company is a tier 1 supplier to
Company - the automotive industry of exhaust
Division of systems & catalytic converters
Tenneco
Automotive
Culver, IN
Quality Engineer
Implemented a quantifiable method to benchmark and initiate continuous
improvement activities for Gap Bulk Density analysis to reduce
warranty claims with Customer by $45 thousand in FY 1999
Initiated & implemented process improvements on the plant floor using
input from process failure mode and effect analysis (PFMEA) and
customer feedback. Input from process operators and error proofing
methods were employed at every opportunity
Trained hourly employees in product gaging, work instructions, and
measurement methodology to support Quality Management System (QMS)
National Standard Manufacturer of sintered nickel 09/95 - 09/98
- Woven Filter and stainless steel filtering
Fibre Division. media used in air bag safety
Mishawaka, IN device systems for the automotive
industry.
Quality Manager
Successfully championed and led company to third party certification /
registration to ISO-9002 / QS9000
Taught Problem Solving Tools, methodology, and discipline to
Management and hourly personnel
Instituted supplier tracking program to a Parts Per Million / Pareto
format reducing inspection detection cost by $45,000 in FY 1996
Developed Production Part Approval Process (PPAP) Program to meet AIAG
and QS9000 requirements
Maintained / managed Total Quality Management function within the
Mishawaka facility
Justified / Expanded Q.A. department by 25% in FY 1996
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Wirekraft Industries, INC. - Burcliff Division South Bend, IN
Manufacturer & recognized leader in appliance market of electrical
wiring harnesses
08/93 - 09/95
Regional Manager Quality Systems
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Ristance Corporation - Division of Echlin Bremen, IN
Manufacturer of insulated XLPE, PVC, & silicone rubber wiring used in
the fabrication of electrical wiring harnesses for the automotive and
appliance sector
03/91 - 08/93
Quality Assurance Manager
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Wirekraft Industries, INC. - Wirekraft Division, Rolling Prairie, IN
Recognized manufacturing leader in insulated XLPE, PVC, & silicone
rubber wiring used in the fabrication of electrical wiring harnesses
used in the automotive and appliance sector
05/81 - 03/91
Quality Assurance Manager
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Hedwin Corporation, LaPorte, IN
Manufacturer of blow molded, injection molded, and vacuum formed
containers used by the chemical industries
05/80 - 05/81
Quality Control Supervisor
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South Bend Toy - Division of Milton Bradley, South Bend, IN
Manufacturer of wheeled good toy line and recognized leading producer
of wooden croquet sets and lawn games
05/77 - 12/79
Production Supervisor / Quality Engineer
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Education
Indiana University at South Bend South Bend, IN
Bachelor of Science degree in Business Administration & Marketing
Purdue University - Technical Assistance Program South
Bend, IN
Lean Manufacturing / Six Sigma - Green Belt Training
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Professional Development
I have completed several courses the past several years in Quality
Management. Courses in Basic and Advanced Quality Management,
Statistical Process Control, Managing Quality, T.O.P.S., Cost of
Quality, ISO9000, ISO9001 : 2000, RAB Certified Internal Auditor
Training, Transition Training to TS16949, Problem Solving, ISO/TS
16949:2002 Internal Auditor Training, Quality System Basics / Layered
Audits and Lean Manufacturing / Six Sigma - Green Belt Training.
These courses were presented by Indiana Technical and Vocational
College, Indiana University at South Bend, Oak Tree & Associates,
NSF , Hunting Quality Associates, and Purdue University.
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PROFESSIONAL AFFILIATIONS
Member American Society of Quality (ASQ)
Member Centre Township Lions Club since 2001 & served as Club
President from 2002 -2004
Member of Indiana University Alumni Association
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