Engineer Quality Assurance

John W. Haley

*** ****** ****** ● Dayton, Ohio **458

(H) 937-***-**** ● (C) 937-***-****

**********@*********.***

SUMMARY

Senior Mechanical/Manufacturing Project Engineer with professional experience in manufacturing

methods, new product development, capital equipment design, lean manufacturing, process

optimization, process capacity/constraint/productivity analysis, continuous quality improvement and

quality control standards. Well versed in manufacturing processes & assembly methods. Proven

project management skills with the ability to accomplish multiple business assignments concurrently.

Proactive, self-motivated, detail-oriented and sensitive to deadlines. Six Sigma Green Belt certified

with creative problem solving skills. Results-driven achiever with exemplary planning and

organizational skills.

Project Management ● Team Leadership ● Supervisory ● Strategic Planning ● Operations Management ●

Lean Manufacturing ● Process Optimization ● Constraint Analysis ● Six Sigma Green Belt Certified ●

Problem Solving ● Troubleshooting ● Quality Control ● Quality Assurance ● Continuous Improvement ●

R&D ● Product Development ● Capital Equipment Design ● Gage, Fixture & Tooling Design ● SolidWorks

PROFESSIONAL EXPERIENCE

Delphi Electronics & Safety Division, Vandalia, Ohio

Senior Manufacturing/Quality-Gage Engineer June 2005 - September 2009

Managed gage/fixture-inspection unit working with customers, multidisciplinary teams and suppliers

leading every phase of projects. Defined gage/inspection plans for all products engineered and

manufactured by division. Sourced gages/fixtures to suppliers for design, build and third-party

certification requirements. Implemented automatic inspection systems to production equipment for

assembly verification. Developed customized quality assurance solutions for dimensional

inspection/testing requirements.

Recognized expert in gages and fixtures; held sole responsibility for gages and fixtures related to all products

engineered and manufactured by the division.

Implemented modular, re-useable check fixture for Roof Rail airbags, resulting in a cost savings of $175K.

Led multiple root cause investigations to determine source for production manufacturing quality issues.

Managed suppliers involved with gage/fixture inspection projects to ensure all requirements were met.

Supervised and trained engineering, operational and technical personnel on all product inspection and testing

equipment at manufacturing plants.

Senior Manufacturing Project Engineer February 1999 - May 2005

Provided leadership and technical expertise to achieve corporate manufacturing objectives for global

production facilities. Managed multiple capital equipment projects for manufacturing operations.

Implemented continuous improvement initiatives using lean manufacturing methodologies to increase

capacity and reduce equipment downtime.

Streamlined manufacturing equipment to maximize operational efficiency for airbag cushion fabrication

processes leading to $250K annual cost reduction while improving quality and reliability.

Selected to troubleshoot production problems at plants in the US and Mexico; consistently resolved all issues.

Installed new manufacturing assembly equipment & tools for multiple programs totaling more than $6.5 million

used in global manufacturing facilities.

Assigned to special team to implement continuous improvement principles and lean manufacturing

methodologies to operating systems throughout manufacturing plants in Mexico.

Developed Control Plans, Process Flow Diagrams and Potential Failure Modes Effects Analysis (PFMEA) for

manufacturing processes.

Implemented Overall Equipment Effectiveness (OEE) methodologies to measure and optimize the efficiency of

production equipment performance, which increased capacity and reduced unplanned machine downtime.

Received a patent award for developing a new airbag folding process used in production, significantly reducing

cycle time and eliminating two operations upstream leading to cost savings of $405K.

Supported plant production launch teams with pilot builds, run at rate, ramp up and start of production.

Supervised operations, trained engineers, operators and technicians on standard operating procedures with

assembly equipment & preventative maintenance procedures in Mexico and Vandalia’s manufacturing plants.

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John W. Haley

Haley-Dusa Engineering & Surveying Group, LLC, Dayton, Ohio

Business Operations Consultant/Manager August 1998 - January 1999

Retained as a Business Operations Consultant/Advisor to lay the foundation for a startup company.

Held the position while completing a MBA degree. Created strategic plans that guided marketing,

business development and financial performance. My father’s organization continues to be successful.

It employs approximately 25 people and generates nearly $3.2 million in revenue per year.

Created business, strategic marketing and organizational plans; generated pro-forma financial statements.

Secured financing and directed coordination for setting up regional offices in Dayton & Cincinnati, OH.

Implemented marketing and organizational business strategies.

Prepared operating budgets, developed and programmed financial reporting systems.

Established managerial accounting programs for financial statement analysis.

Created database programs for accounting, project and invoicing activities.

The Omega Company, Omega International Strategic Business Unit, Dayton, Ohio

Project/Design Engineer February 1996 - July 1998

Managed & designed assembly/test equipment for airbag safety restraint system products.

Researched new tools, products and equipment to be integrated in future design projects.

Coordinated customer design reviews, production equipment trials and final runoffs.

Assisted customers with installation, debug, start-up & training with production assembly equipment.

Process Equipment Company, Design, Engineering & Assembly Division, Tipp City, Ohio

Mechanical Design Engineer October 1993 - February 1996

Supported design & build team with Westinghouse nuclear reactor core fuel rod project.

Designed automated laser welding assembly stations for planetary transmission gear units.

Selected from management for special project involving a new electro-chemical deburring process.

Utilized investment casting processes to develop high precision cathode tooling.

Assigned to research and development team for new precision laser technology applications.

Designed engine pallet conveyor system for Toyota Motor Manufacturing assembly plant.

Responsible for quoting projects, development and design for automated assembly equipment.

Managed projects from quoting stage through assembly, installation and training.

Obtained hands-on experience with assembly of various custom equipment & machinery.

EDUCATION

UNIVERSITY OF DAYTON, Dayton, Ohio

Master of Business Administration (MBA) - 1998

Bachelor of Science, Mechanical Engineering Technology - 1993

PROFESSIONAL DEVELOPMENT, TRAINING & LICENSES

Six Sigma Green Belt Certified, Minitab 15 statistical software training, CAPA, FMEA, APQP, PPAP,

Finite Element Analysis (FEA) training, CNC Programming, Programmable Logic Controller (PLC)

training, Geometric Dimensioning & Tolerancing (GD&T) training, ISO 17025, ISO 14001, ISO

9001:2008/QS 9000 Quality Operating Systems, Measurement Systems Analysis, Design of

Experiments (DOE), Design for Manufacturing/Assembly (DFM/DFA) training, PC-DMIS CAD based

Coordinate Measuring Machine (CMM) software training, Permit 4-OH-113-**-**-***** to handle

and transport pyrotechnic airbag inflators/explosives from the US Department of Justice/ATF

TECHNICAL PROFICIENCIES

SolidWorks, AutoCad/Inventor, CNC Mastercam X3 CAD/CAM, PHP, Microsoft Expression Web, Visio,

Excel, Word, Project, PowerPoint & Access

PROFESSIONAL ACHIEVEMENT AWARDS

Received Patent award for Airbag folding Invention, U.S. Patent #6,588,179 B2

Received (3) Record of Invention awards for other new Airbag manufacturing processes

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