Manager Quality
Resume:
Please Do Not
Distribute Without
My Permission May ‘09
Barry Whitaker
Somerset, Kentucky 42501
606-***-**** home 606-***-**** cell
abndgx@r.postjobfree.com
Career Summary:
Experienced in Welding, Stamping, Assembly, Paint & Quality.
12 yrs of Progressive Lean Management Skill w/Tier 1 Toyota Supplier.
Disciplined in the Toyota Production System & Practice of ‘Toyota Way’ Principles.
Trained in Japan for Startup & Management of American Transplant Companies.
Worked on 22 New Toyota Model Launches w/Equipment Setup, Trials & SOP.
Supported Startup & Operations of Affiliate Facilities in the US and Canada.
Proficient in Microsoft Word, Excel, Powerpoint, Project, & Outlook.
BS in Mechanical Engineering Technology.
Experience:
8/96 to 9/08 Toyotetsu America, Inc. (a tier 1 for Toyota)
Somerset, Kentucky
Producer of Stamped & Welded Underbody Assemblies for Toyota.
10/05 to 9/08 Assistant General Manager, Weld & Assembly
Over 100 production cells, mostly robotic, 2 shifts.
Visual Management, Kaizen, 5S, Kanban, PDCA, TQM, Problem Solving.
Products were radiator support, pillars, control arms and brake pedal assembly.
Staff of over 300 members, 2 mgrs, 4 a/ms, 8 group leaders & 28 team leaders.
Hired and trained replacement manager after promotion to department head.
Achievements
o Safety – Accident frequency rate of 6.
o Quality – Ppm of 5 & certified TS16949.
o Cost – Achieved reduction over $1mil/yr.
o Productivity – Improved over 10% per yr.
o Development – Startup of new $3mil training center.
o Lean – Designated company problem solving trainer.
o Corporate – Lead for Owensboro plant improvement activity.
Supported Texas & Canada facility startup.
10/04 to 10/05 Senior Manager, Weld & Assembly
Split department due to growth and hired additional manager.
Promoted to senior level with responsibility for both departments.
Achievements
o Quality – Received Toyota ‘Break Through Quality Supplier Award’.
o Cost – Reduced finished inventory from 16 to 3hrs.
8/96 to 10/04 Manager, Weld & Assembly
Startup of new tier 1 Toyota supplier company.
Involved with all phases of new factory (construction, policy & procedure,
equipment installation & trials, product packaging, customer relations, etc.)
Achievements
o Production – Expanded plant w/additional product lines.
o Environmental – Certified ISO 14001.
o Cost – Achieved 5% variance on budget of over $15mil/yr.
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5/95 to 8/96 Yamakawa Manufacturing, Inc. (a tier 1 for Nissan)
Portland, Tennessee
Producer of Stamped & Welded Underbody Assemblies for Nissan.
Production Supervisor, Weld & Assembly
Responsible for the off shift welding, quality & shipping operations.
Over 100 processes involving resistance and mig welding.
Products were radiator support, pillars, door guard and dash panel.
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Staff on 2 shift was over 150 members, 6 group leaders and 12 team leaders.
Achievements
o Quality – Improved member compliance with quality procedures.
o Training – Increased skill level of new & existing members.
o Customer – Represented company on the off shift.
10/86 to 5/95 Rheem Manufacturing, Inc. (a medical device company)
Asheville, North Carolina
Producer of Scientific Refrigeration Equipment
5/93 to 5/95 Production Supervisor, Incubator Assembly
Startup of new incubator & blast furnace product line.
Processes were tig welding, electrical & final assembly, testing & shipping.
Staff included 60 members and 4 team leaders.
Achievements
o Materials – Setup parts ordering system for line replenishment.
o Production – Started kanban system for common model parts.
5/90 to 5/93 Production Supervisor, Weld & Paint
Responsible for resistance, mig and tig welding, brazing & paint operations.
Processes included manual, single and multi welders & powder paint system.
Staff included 50 members and 3 team leaders.
Achievements
o Cost – Reduced scrap by creating work standards.
o Quality – Improved adhesion & durability of paint.
5/87 to 5/90 Production Supervisor, Press & Weld
Responsible for sheet metal fabrication and welding operations.
Processes included shears, turret presses, roll forming and brake presses.
Staff of 75 members and 4 team leaders.
Achievements
o Quality – Implemented electrode maintenance & weld testing.
o Efficiency – Reduced die setup & changeover times.
10/86 to 5/87 Production Supervisor, Quality Control
Responsible for all first off product quality.
Supervised 25 quality technicians supporting each production area.
Achievements
o Production – Improved process, work sequence & member training.
o Testing – Purchased, setup & calibration of new test equipment.
Education: Western Kentucky University
Bowling Green, KY
B.S. – Mechanical Engineering Technology, 1986
Personal: Married with two children, willing to travel and relocate.
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