Quality Assurance Manager

Steven L. Lewis

**** ***** ***** * *. Cell 740-***-****

Gallipolis, Ohio 45631 *********@*******.***

I am a goal oriented individual with experience in manufacturing and Quality Assurance

systems relating to plastic molding, metal machining, cold forming, hot forging, bending,

stamping, assembly and coating operations. I have extensive knowledge in Quality System

design and standards ISO 9001, QS 9000, TE Supplement, ISO 14001, & TS 16949. I am

also well versed in SPC, Root Cause Analysis, 8d & 7d, Classical Industrial Engineering,

APQP, FMEA, Control Plans, PPAP, PDCA, GD&T, Lean Manufacturing, New Product

Launches and Quality System Audits.

EXPERIENCE:

GKN Sinter Metals, Gallipolis, Ohio July 2005 – Jan. 2009

Quality Manager

Manage Quality Engineering, Metallurgy Lab, Metrology and Inspection

•

Management Representative for TS-16949 Quality System and Lead Internal

•

Auditor

Member of Site Steering Committee for Lean Manufacturing & Business Segment

•

Champion

Responsible for developing and analysis of Key Metrics such as Quality Cost

•

(reduced by $55,000/mo.) & PPM / Customer Concerns reduced to single digits

applying Deming & Six Sigma Methodology

Site Champion for Lean Standard Work

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Implementation and development of software for document control, statistical data

•

analysis and process capability improvement for cost reduction

Mid West Fabricating Co., Amanda, Ohio March 2004 – Dec. 2004

Corporate Quality Manager

Responsible for all aspects of Quality Management for three manufacturing plants

Program Manager for new automotive product launch for GM & Chrysler including

APQP and Process Sign Off

Project Management for transition from QS 9000 to TS 16949, and Management

Representative for Quality & ISO 14001 management systems

Responsible for Quality & Environmental systems audit program, Key performance

Metrics & Management Review, Continual Improvement activities & Training

Manage staff of Quality Engineers, Floor Inspectors and CMM layout personnel

Lean Manufacturing project coordinator

Aerotek Contract Engineering, Columbus, Ohio April 2002 - Nov 2003

Quality Systems Consultant (Contract successfully completed)

Developed, Documented and Implemented ISO 9001/2000 compliant QMS

Established Quality Manual Policies, Procedures, and level three documents

Trained Executive Management and subsequent levels of the organization on

subjects related to QMS processes, Continuous Improvement, Customer

Satisfaction and Quality System principals

Developed and trained staff in the analysis, goal setting and reporting of Key

Business Metrics for process improvement and cost reduction

Trained Internal Audit staff and implemented QMS audit program

Trained Quality Manager / Management Representative

Schuler Incorporated, Columbus, Ohio Jun. 1997 - Jan. 2002

Quality Assurance Manager

Developed, Documented and Implemented two independent Quality Systems for

registration

- Columbus, OH facility registered to ISO 9001, QS 9000 & TE

Supplement and ISO 14001

- Canton, MI facility registered to ISO 9002, QS 9000 and ISO 14001

Management Representative and Liaison to Customers & Registrar for both

facilities

Developed & Implemented Document Control System and Internal Audit Program

Trained and managed QC Shop Floor Inspectors, Document Control Specialist,

Lead Internal Auditor and Audit staff

Developed, Implemented and Managed Gage Calibration System software

Responsible for Continuous Improvement, development of Ford compliant QOS

program and achievement of the Ford Q1 Quality Award

Responsible for statistical and data analysis, statistical process control, and root

cause analysis of nonconformance’s

ASC Incorporated, Columbus, Ohio May 1995 - Jun. 1997

Quality Assurance Engineer

Developed all APQP for Chrysler LH Program (FMEA, Control Plans, PPAP, etc.)

and Championed successful Process Sign Off

Primary Customer Contact for Chrysler LH Program at Bramalea Assembly Plant

for customer concerns, Root Cause Analysis and Problem Solving 7D

Team Leader for Kaizen, and VDA implementation team

Responsible for Continuous Improvement and managing Shop Floor Inspectors

Kelsey-Hayes Co., Mt. Vernon, Ohio Jan. 1993 - May 1995

Quality Assurance Engineer

Developed APQP for Chrysler Neon & 1996 Chrysler Minivan (FMEA, Control

Plans, PPAP, etc.)

Championed Chrysler Vehicle Launch at Belvidere & St. Louis Assembly Plants

and successful Process Sign Off

Primary Customer Contact for all Chrysler accounts, Customer visits and support

Responsible for plant-wide SPC training, data collection and root cause analysis

Trained QE’s and Inspectors in Root Cause Analysis, Team Problem Solving &

(7D)

Premix EMS, Lancaster, Ohio Sept. 1989 - Oct. 1992

Industrial Engineer

Time & Motion Study and classical IE duties

Development of Metrics and analysis for reporting of process improvement and

goal attainment

EDUCATION:

Completed classes towards MBA degree w/specialization in MIS - Franklin

University, Columbus, OH

B.S. degree - Cum Laude - Technical Administration 2000 - Franklin University

A.A.S. degree - Manufacturing Engineering Technology 1993 Central Ohio

Technical College, Newark, OH

CONTINUING EDUCATION / CERTIFICATION:

Certification Six Sigma Black Belt ExpertRating 2008

Certification Lean Management ExpertRating 2008

Certification Total Quality Management ExpertRating 2008

TS 16949 Lead Auditor Automotive Ind. Action Group 2006

Layered Process Audit - Luminous Group 2004

Lean Manufacturing - Eastern Michigan University 2004

Certified TS 16949 Internal Auditor - Automotive Ind. Action Group 2004

Auditing Core Tools for TS16949 - Eastern Michigan University 2004

Geometric Dimensioning & Tolerancing - Eastern Michigan University 2004

ISO 14001 - Eastern Michigan University 2000

Quality / Business Operating System - Eastern Michigan University 2000

Reliability & Maintainability - Eastern Michigan University 1999

Equipment FMEA - Eastern Michigan University 1999

Certified Quality Auditor - American Society for Quality 1999

Certified QS 9000 Internal Auditor - Automotive Ind. Action Group 1998

Benchmarking - Eastern Michigan University 1998

Short Run SPC - Eastern Michigan University 1998

Quality Operating System - Fairlane Training Center (Ford) 1997

Gage Calibration - Mitutoyo 1997

TE supplement - Eastern Michigan University 1997

QS 9000 - Eastern Michigan University 1997

Statistical Engineering - Dorian Shainin 1993

Time Study - Maynard Research Council 1988

* References Available Upon Request

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