Quality Manager
Resume:
Michael P. Clements
Lynchburg, VA 24502
Home Phone 434-***-****
Cellular 434-***-****
Email: abnp68@r.postjobfree.com
SUMMARY
• Directed $5M projects; designed and developed manufacturing programs in steering
system production per TS-16949 quality requirements in a Toyota Production System to
reduce warranty costs by 50%. Formulated quality policies to support ISO compliances in
the medical device, medium power transformer, and semi-conductor industries as a
Quality Manager to improve customer satisfaction exponentially with an average of a
$25M increase in sales. Led six sigma teams in problem-solving using the fishbone
diagram, root cause analysis, and the 5 why approach to reduce scrap costs by 70% in the
manufacture of Ford F-150s at the Norfolk Assembly Plant as a Quality Director.
Decreased wastes by fifteen percent by utilizing lean manufacturing principles (5S, single
piece flow, co-location of equipment, value stream mapping) and root cause analyses in
the medical device industry. Managed and developed AS-9100, ISO 9001:2000, ISO
13485, TS-16949, and ISO 14001 Quality and Environmental quality systems.
Developed surgical instruments to meet FDA GMPs and conducted internal audits of the
quality system to reduce customer complaints by 80%.
WORK HISTORY
2008-Present Supplier Quality Engineer, Universal Instruments Company, Inc. Binghamton, NY
Managed the supply chain to support costs reduction and continuous quality
improvements in the manufacture of semi-conductor equipment in the electronics
industry to save $650,000 annually. Led projects, developed receiving inspection plans,
formulated supply chain solutions, and supported design revisions via geometric
dimensioning and tolerances to improve customer satisfaction by 75%.
2006 – 2008 Supplier Quality Engineer, JTEKT Automotive Virginia Daleville, VA
Managed the supply chain to assure the quality of steering systems for Toyota, GM, and
Nissan that are manufactured to TS-16949, and ISO 14000 quality system requirements
to improve customer satisfaction by 100%. Performed root cause analyses for permanent
corrective and preventive action to reduce warranty costs $250,000 annually. Led and
trained kaizen teams on six sigma (DMAIC) projects to reduce manufacturing costs by
twenty percent.
2005 – 2006 Quality & Lean Training Manager, Yorktowne Cabinetry, Inc., Danville, VA
Instructed Lean Enterprise Trainers in continuous improvement to support the start-up
operations of a cabinet manufacturer in a new facility. Applied the principles of lean
manufacturing, 5S, single-piece flow, co-location of equipment, and value stream
mapping to add value to the customer to reduce manufacturing costs $525,000 annually.
Color-tested employees for placement in finishing areas requiring customer decisions on
color matching.
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2003- 2005 Quality Engineer, MicroAire Surgical Instruments, LLC, Charlottesville, VA
Performed validation and reliability studies to support the manufacture of surgical
instruments to continuously improve quality. Prepared testing systems for the validation
and installation of autoclave equipment for verifying warranty claims. Developed audit
documentation to support ISO 13485 certification for the medical device industry and to
comply with FDA Good Manufacturing Practices. Developed a supplier certification
program to reduce defects on incoming materials to save $55,000 annually on scrap costs.
Devised sampling plans for incoming materials in accordance with Mil Standard 105E.
2002-2003 Quality Director - Contractor, TDS Automotive, Inc., Norfolk, VA
Managed a Quality System to support a tier zero material planning, logistics, and
sequencing service to Ford Motor Company’s Norfolk Assembly Plant to build F-150
trucks. Solved quality problems using 8-D corrective action methodologies. Facilitated
team improvements to reduce scrap by fifteen percent and lower defect ratios to less than
twelve parts per million (PPM).
2000-2002 ISO Project Manager, Delta Star, Inc., Lynchburg, VA
Successfully achieved ISO 9001:2000 certification within twelve months. Developed
standard operating procedures and work instructions and conducted operator training on
internal auditing processes to comply with the quality system requirements.
Supported the continuous improvement of injection molding operations in coil and
insulator manufacturing. Supervised quality inspectors in reducing costs and
continuously improving product and service quality in transformer manufacturing.
1998-2000 Quality Manager, Techma USA, Inc., Gretna, VA
Developed, validated, and submitted quality control plans for printed circuit board and
wire harness manufacturing in the automotive industry to comply with QS-9000
requirements as a tier three supplier. Prepared PPAPs per APQP requirements as a tier
three automotive supplier of oxygen sensors and wiper motor printed circuit boards.
Managed Auditors and Inspectors in continuous improvement activities.
1998-2001 Instructor, Central Virginia Community College, Lynchburg, VA
Taught the following evening courses: Quality Control, Materials & Processes for
Industry, and Maintenance Planning & Scheduling. Conducted independent study
courses for students to meet graduation requirements as a volunteer tutor.
1992-1998 Quality Manager, Southeast Vinyl Company / Amerimark, Lynchburg, VA
Conducted design of experiments to improve gloss and color yields in an extruded vinyl
siding manufacturing operation. Developed testing procedures for the impact and
shrinkage properties of finished products. Performed studies to reduce scrap by ten
percent in the blending of raw materials. Developed and revised technical specifications
and engineering drawings utilizing ASME Y14.5 Geometric Dimensioning and
Tolerancing. Maintained calibration standards, corrective and preventative action
systems. Improved manufacturing processes and product quality by applying the
principles of lean manufacturing to reduce scrap costs and improve defect ratios.
Conducted gauge and scale repeatability and reproducibility studies to reduce costs.
1990-1992 Quality Systems Analyst, C. B. Fleet Pharmaceutical, Inc, Lynchburg, VA.
Supported the continuous improvement of blow molding operations in the manufacture of
bottles for feminine hygiene products and laxatives. Edited batch records and incoming
inspection plans and procedures to comply with FDA good manufacturing practices to
improve customer satisfaction by 100%. Implemented statistical process control in high-
speed filling, packaging, and packaging operations.
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1988-1990 Quality Control Manager, Wabash Magnetics, Inc., South Boston, VA
Wrote quality manuals to support supplier certification to meet Ford Motor Company’s
Q1 tier-one supplier requirements for anti-lock brake components.
Responsible for the reliability and quality of injection molded coils (epoxy resin), solder
processes, and electronic assembly.
1982 -1988 Power Plant Engineer, Carolina Power & Light Company., Raleigh, NC
Developed balance of plant testing procedures for Pressurized Water Reactors and
Boiling Water Reactors in the construction and outage support operations of power plants
to increase efficiency and availability. Conducted inspections at all witness points in
nuclear power operations in the construction and start-up of the Sharon Harris Nuclear
Power Plant.
EDUCATION
• Master of Science, Administration - 1989
Central Michigan University, Mt. Pleasant, MI
• Bachelor of Science, Mechanical Design - 1982
Norfolk State University, Norfolk, VA
• Lean Systems Certification – 2006
University of Kentucky, College of Engineering
Completed the following courses:
Six Sigma Black Belt Training (DMAIC) Design of Experiments
Failure Mode Effect & Criticality Analyses Team Leadership Training
Lead Auditor Training 5 Why Problem Solving
ISO 9001: 2008 Quality Systems Training MS Office Certification
Kepner Tregoe’s Analytic Troubleshooting SAP Training
MS Excel Level III MS Access Training
Statistical Process Control Toyota Production Systems
COMPUTER SKILLS
SAP, MRP, MiniTab, ERP, MS Word, Excel, Access, PowerPoint, MS Excel SPC, Microsoft
Project, CaWeb, Lotus Notes, Microsoft Office / Outlook, Auto CAD
PROFESSIONAL AFFILIATIONS
Active Senior Member of the American Society for Quality, Chapter 1120, Lynchburg, VA
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