Quality Assurance Project Manager

Strategic quality assurance and operations executive with 30+ years

experience driving quality and operations efficiency for manufacturers of

automotive components and modules, electronics, electromechanical

equipment, metal stamped and machined components. Business Management

systems implementation, Lean Manufacturing champion, multi-site operations,

training/mentoring of engineers managers and process owners, cost

reduction, process and continuous improvement, FMEA, PFMEA, PPAP, APQP,

MRP, Regulatory Affairs, Kaizen, KANBAN, Poka-Yoke, 5 Why, Root Cause,

AS9100, ISO9000, QS9000, TS16949, ISO14000, New Product launch, R&D,

Test/Reliability, Industrial Engineering, and common sense manufacturing.

Cost and scrap reduction, PPM reduction, supplier and customer development,

and strategic systems development.

ACHIEVEMENTS

LEADERSHIP: Develop/implement strategic and production programs reaching

over multiple plant sites and all associates, continuous improvement,

process improvement, logistics, quality assurance, lean manufacturing

systems and environmental impact.

CHANGE AGENT: New systems implementations yield $1M a year in cost savings.

Design and implementation of quality focused teams to address production

and process techniques realizing savings of 20% direct labor costs and 15 %

controllable labor and productivity costs.

EDUCATOR / MENTOR: Design of training curricula; implementation of training

programs; train or mentor junior engineers managers and process owners;

provide training in FMEA, SPC, ISO/QS9000, and Kaizen. Results are improved

process flow, reduced variability, rework reduction, scrap reduction, and

customer satisfaction. Increase the confidence and production of management

teams resulting in 10% improvement in organizational profitability in 18

months.

RESULTS: Cost savings due to new systems implementations of 50% reduction

in field complaints in the first year. Improvement team projects have been

successful in reducing operating cost by up to 30%. Process improvements

were successful in improving first pass yields by up to 10%. Visual

factory management and 5S activities resulted in improved associate morale,

reduction in tool replacement cost and assisted in the reduction in field

complaints.

PROCESS EXPERIENCE

. Metal Stamping, Forming and Fabricating

. Welding (Stainless and Carbon Steels)

. Electronic Assembly

. Injection Molding

. ISO Poly Foaming

. Mechanical Assembly

. Reliability Testing

. Powder Coat, Liquid Spray and ED Painting

EXPERIENCE

2011 to Present Supplier Quality Engineer Hartzell Engine Tech. Montgomery,

AL

OEM manufacturer of Aerospace engine components.

. Manage Supplier Development: Continuously improving the ability of the

supply chain to deliver quality parts on time for lowest total cost.

. Managed supply chain performance to continuously reduce non-conformances

from suppliers.

. Manage the risk of non-conforming material escape into production

. Represent, advocate, and ensure that suppliers' needs and capabilities

are integrated into new designs.

. Support lean initiatives for managing the supply chain.

. Review and approval of new suppliers based on AS9100 requirements.

. Develop, review and approval of PPAP documents to meet AS9100

requirements.

2008 to 2011 Quality Manager, North American Bus Industries, Anniston, AL

OEM Manufacturer of Transit Buses

Processes employed are welding, fabricating, and assembly.

1. Developed and managed Quality Management System to meet ISO 9000:2008

requirements.

2. Managed supply base driving supplier improvement and validating

corrective actions.

3. Managed improvement teams responsible for process capability

improvements to maintain quality and improve efficiency.

4. Design and managed database collection system that enabled formulation

and tracking of process metrics to validate Improvement results.

5. Managed and lead weekly cross functional team meetings to drive

continual improvement on all open issues related to product quality and

process efficiency.

2008 - Sr. Supplier Quality Engineer (Contract) Aerotek Automotive

Inc., Greenville, SC

Tier One Automotive: Dr xlmaier Automotive of America: OEM Manufacturer of

Automotive components to BMW Manufacturing. Processes employed are

injection molding, ISO foaming, and assembly.

. Managed critical supplier performance to ensure process capability to

meet start of production (SOP) deadlines for customer. (BMW)

. Managed weekly cross-functional supplier action team meetings resulting

in reduction of defects by 63%.

. Managed approval of PPAP submissions for tier one automotive supplier.

. Lead customer quality meetings to Provide BMW management with critical

clean points and actions taken vital to protecting BMW processes.

2006 to 2008 Sr. Supplier Quality Engineer Innertech Spartanburg,

SC

Tier One Automotive: Division of Magna International.

Design, develop and manufacture automotive systems, assemblies, modules and

components to supply BMW Manufacturing. Processes employed are injection

molding, ISO foaming, bonding and assembly of interior automotive

components.

1. Developed and maintained Process Flow Diagrams, Control plans, and

FMEA's for automotive business.

2. Managed supply base to ensure parts submission and quality met TS

16949 and customer requirements.

3. Managed CS2 inspections of supplier product to protect internal

process from nonconforming material.

4. Statically analyze material critical characteristics to drive supplier

improvement. Improvement effort resulted in $1M of cost being saved.

2006 Sr. Quality Engineer (Contract) Aerotek Automotive Inc.,

Greenville, SC

Tier One Automotive: Plastic Omnium Inc., Faurecia Automotive Interiors:

OEM Manufacturer of Automotive components to BMW Manufacturing. Processes

employed are injection molding, ISO foaming, painting and assembly.

. Developed and maintained Process Flow Diagrams, Control plans, and

PFMEA's for automotive business.

. Responsible for troubleshooting process deficiencies and identifying

corrective actions to prevent reoccurrence.

. Coached process owners in developing problems solving teams utilizing the

8D process to facilitate continuous improvement.

. Developed and maintained PPAP submissions for a tier one automotive

supplier.

2004 to 2005 Quality Assurance Manager Force Protection Inc. Ladson, SC

Tier One Armored Vehicle: OEM Design, manufacture, and marketing of mine

and blast protected heavy trucks for the US Government with sales of $42M.

Major customers are U.S. Marine Corps and U.S. Army. Processes employed

are, welding, metal fabrication, painting, and assembly.

. Reported to the Quality Vice President with 4 direct and 20 indirect

reports in 2 plants of 300 employees.

. Managed the design and implementation of the Quality System that enabled

company to successfully complete DOD contractual requirements and lead to

additional Marine Corps orders.

. Acted as Customer Representative for the organization to the US

Government (DCMA) ensuring contact specification was achieved.

. Managed EH&S department ensuring that site air permits and other

regulatory requirements were compliant to state and federal laws.

. Responsible for ensuring that production documents were in compliance

with DOD requirements to achieve progress payments on a critical

contract.

. Managed and developed initial production product approval process and

supporting documentation to achieve DOD acceptance of new product line.

Resulted in achieving cash flow at an integral junction of the company's

growth.

2002 to 2004 Quality Assurance Manager SC Yutaka Technologies, Lugoff, SC

Tier One Automotive: OEM Manufacturer of motorcycle, ATV and Automotive

components to North American Honda Manufacturing. Processes employed were

machining, stamping, heat treating, ED Paint, Top Coat Paint, Robotic

Welding, mechanical assembly, and metal fabrication.

. Report to the AVP/Plant Manager in a $32M facility of 600 employees.

. Managed the design and implementation of the ISO 9000-2000 and ISO 14001

systems which resulted in registration of the systems in 11 months.

. Train/mentor 15 process leaders resulting in increased productivity of

15%.

. Project Manager for document control software (MQ1) implementation for

automotive quality systems. Successful implementation allowed for more

efficient document control of PPAP, Engineering drawings and associated

documents required to maintain TS16949 required documents

. Project Manager for a successful plant wide implementation of Quality

Circle Teams. One team was successful in winning fourth place in the

North American Honda Team competition

. Lead Kaizen team that successfully improved paint processes to reduce

defects and improve product quality resulting in a 10% improvement in

through put.

1999 to 2002 Sr. Quality Engineer Cooper Lighting, Americus, GA

Manufacturer of incandescent, fluorescent, exit and emergency lighting

systems with total corporate sales of $4.46B a year.

. Report to the Division QA Manager with 3 direct reports responsible for 2

plants Quality Systems employing 1,800 associates.

. Trained other division Manufacturing Engineers to successfully utilize

FMEA tools for all products produced at the Elk Grove, Il facility.

Successful documentation facilitated an efficient product move to new

plant producing the products.

. Managed ISO 9001:1994 implementation project through successful RAB

registration.

. ISO Management Representative for two plants reporting to senior

management on systems performance.

. Designed database to initiate ppm tracking of customer satisfaction

trends and improvement efforts resulting in a 50% reduction the first

year.

. Performed internal audits at three plant location within the division to

improve quality systems.

. Designed and maintained metrics utilized by senior management to

continually improve business performance.

1998 to 1999 ISO Administrator Nakanishi Manufacturing

Winterville, Georgia

Tier One Automotive: OEM manufacturer of metal stamped and injection molded

bearing retainer components for automotive assembly plants in North

America.

Developed Quality Policy Manual and supporting documentation for QS

9000

Quality System.

. Designed and implemented QS 9000 Quality Management System to prepare

organization

for ISO registration.

Implemented ISO document control software (Power way) to effectively

control

QS 9000 documents and records required for QS registration.

1994- 1997 Sr. Quality Engineer, Mitsubishi Consumer Electronics,

Braselton, Georgia

OEM consumer electronics manufacturing facility with a capacity of 550,000

units per year.

. Developed AIAG supplier quality system that encompassed PPAP, new

Supplier Approval Process, and JIT dock to line suppliers.

. Team leader for the implementation of TQM within the organization.

. Supervised Quality Technicians in the performance of process quality

improvements.

. Developed and implemented ISO 9000 procedures where none previously

existed. Resulting in successful RAB certification of the QMS.

. Team leader for numerous KAIZEN improvement teams resulting in

substantial cost savings through elimination of non-value added

processes.

. Supplier site audits to troubleshoot processes requiring continuous

improvement efforts to reduce nonconformance's received at dock.

1990 to 1994 Production Supervisor, Panasonic Automotive, Peachtree

City, Georgia

Tier One Automotive: OEM manufacturer of car audio components for Toyota

and Honda automotive assembly plants in North America

. Responsible as Customer Liaison for Toyota Manufacturing (TMMC), NUMI)

facilities being supplied product from process I managed.

. Developed FMEA's, Control Plans and other associated documents to

successfully, submit PPAP's for new model launches.

. Report to the Production Manager with 3 direct reports and 30 indirect

reports.

. Implement Kaizen methodologies into the Toyota production line resulting

in a decrease in rework of 15% and an increase in productivity of 22%.

. Train and mentor production employees; increase throughput 2.5% by

process improvements; increase production by 42% by implementing a

"friendly" competition between 3 production lines for non-monetary

rewards.

1987 - 1990 Supervisor Quality Assurance NEC Technologies, McDonough,

Georgia

OEM manufacturer of color television, computer monitors and laptop

computers to support North American sales.

. Managed supplier, in-process and customer quality program to effectively

meet the expectations of both the production department and OEM

customers. Customer base included Dell Computer, NCR, Yamaha Electronics

and AT&T in a Lean manufacturing environment.

. Cross-functional Team Leader for new product introduction implementing

process controls, training and quality control procedures to shop floor

process owner teams. Ramp up time was reduced and production requirement

was achieved.

. Developed and trained Quality Circle Teams (ZD Teams) that effectively

reduced operational cost and quality defects within the processes.

. Customer liaison for plant quality programs.

1977 - 1987 Engineering Technologist RCA Consumer Electronics Corp.

Indianapolis, In

OEM Design Center for color television products for support North American

Manufacturing operations.

. Supervised 30 Engineering Technicians conducting reliability testing on

initial samples (PPAP) submitted by supplier to qualify for shipment to

manufacturing plants.

. Developed test conditions to determine component characteristics

conformance to design engineering specifications.

. Designed, developed and fabricated electronic component test fixtures to

improve testing laboratory processing time.

. Analyzed test data to ensure conformance to engineering design

specifications.

. Designed and Developed computer programs to automate test functions of

the laboratory.

EDUCATION / TRAINING / CERTIFICATION

M. S., Quality Service Management Mercer University Macon, GA 2000

B.S., Business Management Mercer University Macon, GA 1990

A.S., Electrical Engineering Technology U.S. Navy Memphis, TN

1977

A.S., Criminal Justice Vincennes University Vincennes, IN

1975

FARO CMM Training 2009

Deming Systems Thinking, Apt Leadership 2005

North American Honda Continuous Improvement through Teams 2003

ISO 9000:2000 Lead Auditor Georgia Institute of Technology,

1999

FMEA, AIAG 1999

ISO 9000 Internal Auditor Georgia Institute of Technology, 1998

Mitsubishi Kaizen Deployment 1997

Supplier Management in a JIT Environment 1996

SPC 1990

NEC Quality Circle Team Building 1988

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