Quality Assurance Engineer

Philip R. Ogrod

**** ******* ****, *********, ** 45305 (Dayton area) 937-***-**** (H) 937-***-**** (M) abnrew@r.postjobfree.com

SUMMARY A Quality Professional with over 16 years of experience; familiar with various aspects of engineering and

management from advanced quality planning, operations, to systems, auditing, and supplier management.

Adept at launching a product, carrying it through to production and beyond to ensure customer satisfaction,

then auditing the results for improvements as well as conducting necessary training to assure understanding of

the requirements.

EDUCATION BS - Industrial & Systems Engineering, The Ohio State University (1989)

MS - Teaching, The University of Dayton (1997)

SKILLS Quality Management Systems Auditing Customer Service/ Ethical

System Analysis/Analytical Supplier/Vendor Control Training

Project Management Quality Assurance Product/ Process Auditing

Team Leadership Supervision/Coaching Detailed/Persistent/Patient

PROFESSIONAL

EXPERIENCE Faurecia Exhaust Systems, Inc. – Franklin, OH Plant January 1996 – March 2009

formerly (AP Automotive Systems, Inc.); formerly(Tube Products Corporation, Inc.)

(Global tier1 manufacturer of OEM exhaust tube, muffler, converter & manifold systems for truck and

automakers worldwide- customers Ford, GM, Mazda, Chrysler, VW, Kia, and interplant Faurecia)

Processes: assembly, welding, laserwelding, stainless steel tube forming/bending, cutting, end forming,

press; test lab

Supplier Quality Assurance Engineer – Supplier Development/QA/Purchasing

-- Issued & tracked supplier rejects and PPM; reported results to management monthly and daily

-- Worked with suppliers on corrective actions for timely completion and supplier improvements

-- Enacted containment activities to protect production and customer from supplier issues

-- Reviewed and approved annual supplier PPAPs; met with supplier representatives

-- Interfaced with JDEdwards / AS400 for supplier applications/debits

• 10% decrease in scrap / rework because of supplier development efforts in 2 months

Sr. Quality Assurance Engineer/ TS16949 Lead Auditor– Program/ Quality Systems

-- Set up control plan audit schedules and layered process audits; conducted extensive audits &

training for each

-- Conducted ISO:TS16949 & ISO:QS9000 internal audits for plant and supported audits for sister

plants; provided/conducted audit training; developed audit training class; completed turtle

diagrams for processes

-- Assisted in revamping manage the change process for plant and division interface; wrote

Engineering Change Requests for product improvements and cost reductions – resulted in

systemic fix to reduce PPM by 25% for service part applications

-- Established pre-production, production & service control plans for new and existing programs,

specified production inspection, worked with process engineering to identify and implement poka

yokes for processes; identified weaknesses in systemic processes for quality and production and

implemented corrective actions to make improvements/ 8-D; documented in PFMEA process;

designed some in-process gauging for process evaluation

-- Defined and tested product to specifications (test methods, frequencies, etc.); reviewed internal &

external specifications

-- Implemented seven quality basics within the Franklin Plant- including SPC applications as

needed; increased visual management & provided for containment activities & quality alerts for

all customer issues

-- Worked with customer to obtain timely approvals to ship product (responsible for PPAP

-production part approval process- packages & submissions/ approvals; SREA process)worked

with assembly plant liaisons as well

-- Hands-on leader; interfaced with customers, account managers, project managers, suppliers,

engineers, manufacturing, logistics, production operators, purchasing and quality in relation to

the launch and manufacture as well as plant to plant product transfer of exhaust system

assemblies

Philip R. Ogrod Page 2

-- Coached and mentored other engineers; acted as a resource for others

-- Participated in customer design reviews, technical reviews; supported customer builds

-- Provided support for Q1 implementation plans and MMOG implementation; reviewed Ford SIMs

-- Implemented quality systems through a formal program of AQP, drawing & specifications

review; generated documentation such as control plans, PFMEA, inspection, gauge, operation

instructions; capability studies; gauge designs, gauge R & R

• 10% reduction of cost and number of part numbers by commonizing part numbers

through engineering change management system and SREA processes in 12 months

Quality Manager –

-- Managed QA functions and QA department for facility

-- Management Representative for external audits; Tracked all Quality metrics for plant

• Successfully organized efforts to gain initial Ford Q1

Quality Engineer – Program & Process –

-- Experience and contact with OEMs including GM and Ford

-- Participated in plant startup for new products; implemented SPC, corrective actions using 8D/QRQC

-- Accomplished timely PPAP for GM & Ford products from APQP through in-series production &

service; worked with production on various instructions and statistical analyses

• ISO:QS9000 Team Leader for successful 3rd party registration in 18 months; developed QMS &

all procedures & W/Is

• Developed Internal Auditing training materials for internal audit classes, layered process

auditing classes, and TS16949 overview classes – saving costs for outsourcing of training for plants ($10K

annually)

Textron Automotive– Randall Division - Wilmington,OH/Cincinnati,OH Jan 1993-Nov 1995

(Manufacturer of automotive fuel filler tube assemblies for OEM automakers worldwide- customers Ford, GM,

Chrysler, Nissan, Subaru)- Processes: Welding, brazing, tube making, forming/bending, cutting, assembly,

electrostatic painting, corrosion resistant coatings, end forming, press; test lab

Quality Assurance Engineer – Wilmington Plant

-- APQP/ Quality Planning for product launch and in-series production for Chrysler, Ford, GM,

Nissan, Subaru products; conducted audits

-- Implemented quality systems for fuel tube systems; Completed PFMEA, control plan, process

flow diagrams, inspection instructions, operation instructions, capability studies, gauge R & Rs,

procedures; completed part testing/ DVP&R

-- Extensive customer & supplier contacts & relationships established; Coordinated customer sign-

offs; tracked customer & supplier PPAP submissions; completed part layouts utilizing CMM

Division Quality Assurance Engineer- Cincinnati Division Office

-- Traveled among six plants to assist with product launches and APQP documentation for in-series

production

-- Trained Randall personnel in SPC, PPAP, APQP at Randall Plants and Division QA Conference

-- Compiled division PPM reports for management review ;Assisted in strategic planning for metal

products for division

• Completed DOE – Taguchi Methods for process optimization to reduce scrap and

customer PPM by 25% on staking operation

• Completed DOE – Taguchi Methods to optimize spotwelding operations to reduce scrap

and rework by 10%

CERTS./ ISO:TS16949 Lead Auditor (OMNEX)

TRAINING/ American Society for Quality (ASQ) – Senior Member, Certified Quality Auditor (CQA)

ORGS. Institute for Industrial Engineers (IIE) – Senior Member

Tube & Pipe Association International (TPA) Member

Ohio State University Marching Band Alumni –TBDBITL

PFMEA training(AIAG & FORD), APQP training, AIAG PPAP training, GD&T training, Taguchi

DOE training, ISO:QS9000 & ISO:TS16949 Internal / Process Auditing training; 8-D(FORD TOPS

training), Ford Q1, Procedure writing training, Gauge R & R/ANOVA, AIAG Core Tools,

MINITAB statistical software, AQuA software, GageTrak; Layered Process Auditing, Safety

Auditing

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