Quality Engineer

Dan Walters 513-***-**** cell Middletown, Ohio

SUMMARY

For the past 25 years, I have been involved in all aspects of Supplier

Quality, mechanical inspection methods, inspection planning, gage

design, special process’s, Lean thinking, Metrology, calibration, and

project management, of Aerospace, HVAC, Medical Device and industrial

hardware. My computer knowledge includes, large company mainframe

applications, AUTOCAD, UNIGRAPHICS, CMM’s and Microsoft Office Suite.

Part of my strength is the ability to coordinate all inspection

activities within a highly technical manufacturing environment,

applying creative and practical techniques to meet corporate deadlines.

EDUCATIONAL BACKGROUND (also see addendum)

Cardinal Stritch UNIVERSITY, Milwaukee, Wisconsin

BSM degree Total Quality Management TQM (3.75 GPA) December 1996

Front Range College (Major: Machine Drafting Technology, Computer Aided

Design) AUTOCAD

AAS degree 1995; 3.929 GPA 110 cr. Hrs. Westminster, Colorado

PROFESSIONAL EXPERIENCE

PRATT WHITNEY Engine March 2005 to July 2009

Supplier Quality Assurance Representative. Remote engineer servicing

supplier factories in Ohio and Kentucky. Duties .. First article

inspection approval, Engineering Source Approval, SQA AS9100 audits,

process certification, KEY characteristics, Escape investigation,

Source qualification, JSF new product launch support and over site.

Airfoil mfg, brackets, complex assemblies (fuel pumps and coolers )

complex machining, EDM, ECM, castings, forgings, composites, SSME

harness‘s, plating, coatings, special processes.

CARRIER CORPORATION Aug 2002 to March 2005

McMinnville, TN (1500 employees, 600M sales)

Worlds largest manufacturing plant site for commercial HVAC units

Supplier Quality Manager, Supplier Engineer; Sr. Analyst – Since the

announcement of plant closure a member of the push team, focused on

outsourcing the 400k sq ft sheet metal fabrication shop. Expert in SQA,

Planning, writing procedures, MDR, CCA, Calibration, Root Cause

analysis, Quality system surveys, supplier selection, capability

studies, design reviews, KEY design features and mistake proofing.

Achieving Competitive Excellence

WRIGHT MEDICAL TECHNOLOGY, (DOW CORNING) MAR of 1997 to 2002

Arlington, TN (650 employees, 350M sales)

Medical Device: Orthopedic implant manufacturer, hips, knee, spine and

custom implants with associated instrumentation and devices.

Senior Engineer; Hip Stem & Acetabular Implants and Surgical Instruments

Manage projects such as product launch and new equipm

• Prepare extensive quality plans for LEAN manufacturing operation

• Designed easy to use, efficient affordable gages and fixtures,

Organized hip stem inspection, writing work instructions & procedures.

Consolidated inspections to save time and improve quality. Authored FDA

compatible quality control visual acceptance criteria for implant

cosmetics. Cross functional FMEA. Rapid prototyping. Vendors.

• Installed process controls, sampling plans, Instituted Statistical

Process Control, optimizing processes with Six Sigma techniques;

Process capability studies, Gage R&R, Material Review Board, CP CPK,

SPC, FDA, ISO, PPAP, SQA.

• Processed customer Complaints, determining root cause failure analysis

• Took charge and justified funding for LEITZ PMM for acetabular implant

inspections. New piece of equipment decreased inspection times from 45

minutes per part to under 3 minutes. The new method was the driving

force behind the company’s ability to develop and manufacture more

parts inhouse and meet sky rocketing sales demands. Purchased several

expensive pieces of inspection equipment and machine tools. Developed

inspection methods and routines to improve gage R&R and quality

DRESSER INDUSTRIES, WAUKESHA ENGINE DIVISION (Halliburton)

Jan. 1994 to Mar 97 Waukesha, Wisconsin (1,000 employees and 250m

sales)

Heavy industrial Natural Gas and Diesel Internal Combustion Engine MFG.

Senior Engineer

Capacity planning for inspection departments, Total Cycle Time

Reduction, Supplier Quality Measurement, Design review of parts, ANSI

14.5Y GD&T, Setup and Coordinate Process & Machine Capability Studies,

MRB, Quality Tools & Principles, SQA, SCAR, RRCA, TCT, Lean, U-cells,

Pistons, Crankshafts, head, valves, Gears

Supervise (24) Inspectors and (3) Manufacturing engineers. Prioritize

and coordinate Zeiss, DEA and Cordax CMM activities, Manager of

Calibration Laboratory, MRB activities; all aspects of machining

inspection, special processes (Heat treat, plating, NDT and fab),

assembly and test,

•Formulate or help formulate QA/QC ISO 9001 compatible Quality Operating

Procedures, Quality Assurance Instructions, Supplier Quality

Procedures, Department Work Instructions and Automated Inspection

Instructions, Peter Thomas

•Drafted Process Control section of Malcolm Baldridge Quality Award

application,

•ISO 9001 LEAD AUDITOR, supervise internal auditing groups, Phillip

Crosby

•Managed capital project budgets, quality improvements, in excess of $3

million

SUNDSTRAND CORPORATION (United Technologies)

1976 to Oct. 1993; 4 PLANT SITES IN 3 STATES, Illinois, Colorado &

Iowa

SUNDSTRAND ADVANCED TECHNOLOGY GROUP, AEROSPACE CORPORATE HEADQUARTERS

Rockford, Illinois (site with 4000+ employees, billion dollar corporate

sales) Mil-Q-9858. Military and Commercial application electric power,

gear actuation, fuel pump and mechanical systems.

Supplier Engineer; Sr. Analyst Raw Material Procurement Quality

Assurance

•Vendor Q.A., surveys, cause and corrective action, accounts included

Foundries, Steel Mills, Machine shops, special process suppliers

(platers, heat treaters, welders, plastics, laboratories, EDM etc),

lead supplier reduction projects

•Expert at Complex casting layouts, sand, die, investment, lost foam ;

Supplier Management using SPC Methodology as tool for problem solving

•Expert consultant on ANSI 14.5Y Geometric Tolerance, design review, KEY

design features, process produce-ability & inspect-ability

SUNDSTRAND ROCKFORD MANUFACTURING, PML

1991-1992 Rockford, Illinois (site with 200 employees). Mil-Q-9858

High volume Numerical Controlled machining of large complex magnesium

gear box housings and assemblies.

Supervisor of Inspection Plants (1) & (2)

•Supervised (16) Q.C. personnel performing highly detailed mechanical

inspections, operating and programming CMM (DEA and Boice),NDT(X-ray,

Zyglo and Magna-flux). Scheduled work through (9) coordinate measuring

machines (CMM), Final, Receiving, In process Inspection. Programmed CMM

and Quality Planning, MRB and Root Cause analysis.

SUNDSTRAND Advanced Technology Group (ATG)

1980 – 1991 Denver, Colorado Mil-Q-9858

Fast paced producer of complex precision components including turned,

heat treated and ground gears and shafts.

CHIEF Inspector, Pre-Prod (prototype & black hole)

•First Article, Military Data Packs, operated and programmed: DEA,

Boice, Moore, Leitz, Portage, Brown & Sharpe Coordinate Measuring

Machines; Taguchi methods

Operated and programmed GEAR inspection equipment: Fellows, Hofler,

M&M, Moore

•Metrology Laboratory calibrations measuring and test equipment, adjust

and calibrate; Deming philosophy; Juran quality control, individual

commitment

SUNDSTRAND HYDROSTATIC Transmission Plant

1976 – 1980 Ames, Iowa (1220 employees)

Tool & Gage Inspector and Mechanical Inspection, Quality Control

•Metrology Lab. Calibrations, CMM, GDT., Gear inspection equipment

•SAE and automotive standards; Complex Casting Layout on open plate and

Portage

ADDENDUM

Certificates from Sundstrand Corporation

Supervisory Management Training

Producing Results with Others (PRO)

Team Approach to Problem Solving (TAPS)

Statistical Process Control

ISO 9000, Mil-9858, QS 9000 Overview

Design of Experiments (DOE)

Situational Leadership I & II

Boeing's Advanced Quality System (AQS & SQC)

KEY Features Design Review

D1 9000 program; BOEING Total Quality Management,

TQM Joiners & Associates, Self-Directed Work Teams

Gear Inspection Geometry

Attended 25 week course for Quality Engineering ASQC

Course work at Cast Metals Institute, Chicago

American Foundryman Society

Intro to Metal Castings

Casting Defects and Analysis

Rapid Proto-Typing

Certificates from Dresser Quality Institute

ISO 9000 training, EXCEL Partnership (consultants)

ISO 9000 Lead Auditor training, EXCEL Partnership

ISO 9000 Documentation / Implementation, EXCEL

Philip Crosby, Quality Education Systems (QES)

Total Cycle Time; Peter Thomas Group

Advanced GD&T 14.5 1994

Pratt Whitney and Carrier Corporation … United Technologies Corporation

ACE Business Process, Achieving Competitive Excellence; QCPC,

Mistake Proofing, Relentless Root Cause Analysis, Process MGMT, Market

Feedback, AS9100 auditing, process certification, Risk analysis, GOLD

Business Ethics – Business Certificates; Antitrust – dealing with

customers, distributors, dealers and competitors; Product Substitution

Other Technical Certificates

CORDAX CMM; DEA CMM, Tutor; ZEISS CMM, U-SOFT; LEITZ PMM, Quindos;

Brown & Sharpe CMM, MM4

GEAR Metrology Clinic, AGMA/SME,

UNIGRAPHICS, Advanced GD&T Concepts, Six-Sigma-Greenbelt, Lean

Manufacturing

Value Stream Mapping, Tennessee Tech, Wright Medical/Dow Corning

Other AWARDS AND ACHIEVEMENTS

EAGLE AWARDS, Pratt Whitney, 2005, 2006, 2007, 2008, Recognized by PW

management as outstanding contributor on high priority projects.

TEAM BUILDER AWARD, Wright Medical, Recognized by Director of Quality

for taking charge on complicated acetabular bipolar implant issue. Changed

process, inspection methods, designed assembly fixtures and recommended

product design changes. Because of endeavor, Company met $400k Japanese

sales deadline

Colorado State Board Vocational Credential Technical-Instructor AutoCAD

Employee of the Month; McDonald/Douglas Aircraft project, Sundstrand

"OUTSTANDING CONTRIBUTOR" AWARDS, peer review and recognition,

Sundstrand

Machinist Apprenticeship, A.B.CHANCE, Bournes Inc, Ames, Iowa 1973

OTHER INTERESTS

•American Society of Quality Control, Society of Manufacturing Engineers and

American Foundryman’s Society

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