Quality Assurance Manager

Dennis Sutton

**** * ******** ****** • Madison, WI 53717 • C: 608-***-**** • H: 608-***-****

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

BACKGROUND SUMMARY

Quality Manager experienced in ISO 9001:2008, TS-16949, cGMP systems, continuous improvement,

Lean and the Six Sigma Processes. Highly effective service oriented leader with a proven record of quality

management, complaint resolution and delivering increased customer satisfaction. Experienced in the

rubber, aluminum die-casting and plastic packaging industries. Skilled in developing teams and leveraging

human resources to deliver excellence in quality which consistently achieve business results.

P ROFESSIONAL EXPERIE NCE

PLACON CORPORATION, Fitchburg, WI 2006 - 2008

Thermo formed plastic for the Food, Medical and Retail markets with $100 million in sales.

Quality Manager 2006 to 2007/2007 to 2008

Reported to the CEO and managed a staff of eight quality professionals providing support for the entire

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company’s sales.

Implemented ISO 100,000 clean room procedures.

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Trained cGMP to supervisors and quality technicians

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Reorganized company ISO system to conform to current ISO 9001:2000 Standard within six months.

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Established Corrective Action teams to focus on customer Issues and trained 28 employees in 5-Why Problem

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Solving and Root Cause Analysis. Implementation of these process reduced customer complaints over 50% in

one year.

Implemented 24/7-production audit process to eliminate controllable/predictable product defects. This resulted

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in the reduction of customer complaints by over 50%.

Hired four Quality Techs to cover all shifts 24/7 to assist with standard review, hold material release, process

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audits, product audits and specification awareness for the operators. Resulted in increased custom er service.

Director of Manufacturing 2007 - 2007

Directed 10 salaried and 285 hourly employees in daily production duties.

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Utilizing the back-to-basics approach for process improvement and operator involvement increased machine

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uptime 15% and reduced scrap 5%.

Spearheaded the implementation of the Continuous Improvement process, which increased operator

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involvement. 15% of the work force was involved in projects that resulted in potential savings in excess of

$300,000 in six months.

Coordinated the various aspects of production, including maintenance, to ensure that shipments were made on

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schedule 98% of the time.

MADISON-KIPP CORPORATION, Madison, WI 1994 - 2006

Aluminum Die casting and high speed machining for the automotive market with sales of $65 million in

2006.

Quality Assurance Manager 2001 - 2006

Reported directly to the VP of Engineering and coordinated five direct reports and 22 hourly employees in the

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Dimension & Gage and Floor Inspection areas.

Spearheaded efforts to ensure TS-16949 Certification in 2001 and upgraded to TS-16949: 2002 in Oct 2004 to

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comply t o automotive directive.

Successful in reducing the external plant PPM from 2150 to 268 using mistake proofing methods and 5-Why

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Problem Solving methods. Implemented the ETQ software to track corrective actions.

Served as member of the Management team, which implemented Lean Manufacturing principles plant wide.

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Set up value streams and then each value stream completed 5 S and value stream mapping. Madison-Kipp

realized a 12% reduction in workforce over three years due to value stream mapping efforts.

Established, organized and implemented a Material Review Board that helped reduce waste 34% in 2004.

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Fair Oaks Facility Plant Manager 1999 - 2001

Managed 12 direct reports and 180 hourly employees across three shifts.

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Created and successfully implemented a 24/7 rotation by involving the employees upfront and allowing them

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to set the rules they would operate to for VW oil pan production cell. This resulted in a self-managed work

group.

Aluminum Plant Manager 1998 – 1999

Developed and implemented the use of Daily Report Sheet to highlight the issues and opportunities during the

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previous 24-hour period.

Implemented Daily Production meetings to focus on uptime, reasons for downtime and scrap issues. The

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focused meetings were instrumental in reducing scrap from 9% to 7% in one year.

Dennis Sutton – Page 2

Zinc Area Manager 1996 - 1997

Improved labor relations through successful dialog between employees and management. Resolved

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issues pertaining to seniority, job assignments, hours, overtime, safety and lost time injuries. Open

dialog successfully resolved union organization vote in 1996.

Quality Manager 1994 - 1996

Reported to VP of Quality with five direct reports and 22 hourly employees in the Dimension & Gage and

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Floor Inspection areas.

Co-lead efforts to secure QS9000 certification in1996.

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Directed APQP and FMEA activities to meet requirements pertaining to new part design and design revisions.

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Established open communication with customers by initiating "in person" visits to customers where they were

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encouraged to describe their concerns pertaining to quality. This established a "one person" contact between

the customer and company, which reduced customer complaints by 15% first year.

S PRINGS W INDOW FASHIONS (Graber Division) Middleton, WI 1991 - 1994

Quality Assurance Manager

Reported to Director of Engineering and managed staff for auditing, monitoring in plant process and receiving

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inspections.

Developed and analyzed statistical data and product specifications to determine standards, which reduced

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incoming inspection time by 50%.

Established proposed quality and reliability expectancy of finished product for operator testing, which reduced

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off line inspection by 30%.

P RINCIPAL FINANCIAL G ROUP 1990 - 1991

Agent dealing with Financial Planning, Life Insurance and other related product. Working in conjunction

with my brother and servicing his client group.

G OODYEAR TIRE & RUBB ER CO ., Lincoln, NE 1976 - 1990

Quality Assurance Manager 1989 - 1990

Directed the operation of 48 QA units within the plant; including SPC implementation and overall responsibility

for plant systems to assure quality of the outgoing product. Re-instated customer contact at the assembly plants to

prevent and assist with problem resolution. Improved overall plant systems to conform to the new Ford Q-101

guidelines.

Hose Business Center Manager, Lincoln NE 1987-1989

Managed efforts of 620 employees, including staff, which involved safety management, productivity reviews,

waste coordination and departmental budget formulation. Participated on the Plant Operating Committee, that was

the overall governing body of a plant that included 1600+ hourly and 300 staff employees. The department realized

a 40% productivity increase and 14% waste reduction during the two years.

Quality Assurance Manager, Textiles, Cartersville, GA. 1986 - 1987

Coordinated the Quality Assurance functions of the four Goodyear Textile Mills.

Quality Assurance Manager, Lincoln, NE 1984 - 1986

Plant awarded Ford Q-1 quality award.

Quality Assurance Leader, Lincoln, NE 1979 - 1984

Supervisor, Lincoln, NE 1976 - 1979

E DUCATION / T RAINING

MBA, Cardinal Stritch University, Madison, Wisconsin, 50% completed

BS, Business Administration, University of Nebraska, Lincoln, Nebraska

QS-9000 seminars AIAG and University of Wisconsin

5 S Training, Productivity Inc., Phoenix, AZ

Business Center Training, Goodyear Tire & Rubber Co.

Military - U.S. Navy / Honorable discharge

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