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Quality Assurance

Edmond, Oklahoma, 73034, United States
May 18, 2013

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John E. Callery

**** ********** ***

Edmond, Oklahoma 73034



Over twenty five years of results-oriented manufacturing experience at

domestic and foreign plant locations in various functional areas of

Manufacturing Management, Production, Engineering, Supplier Quality, and

Quality Control. Proven track record and strengths in achieving bottom-

line results for quality, growth, profitability and increased efficiency.

A multidisciplined, hands-on professional offering outstanding leadership

qualities, training and expertise to include:

o Strong working knowledge of Toyota Production System - Lean Manufacturing


o New plant start-ups, major model changes, and new model launches,


o Vast experience working in different countries - with varied cultures.


o Extensive background in vehicle specifications and government regulations

o Over 9 months training in Japan with Toyota Motor Corporation.

o Over 500 hours of training courses completed at Toyota Motor Mfg. USA.

o Languages: Spanish (fluent), Thai (proficient), Mandarin (working


o Expert skills in the areas of leadership, training, coaching, and overall

people development

o Successful at driving organizations to achieve business plan objectives,

including stretch targets. SQPRC

o Strong working knowledge of SPC, TQM, Six Sigma, Red X, PFMEA, VSM and

all major quality tools

o Excellent Project Management skills

o Management of regional and global processes and initiatives

o Supplier Quality development - APQP, PPAP and related processes

o Extensive experience with QS-9000, ISO-9001, TS-16949 implementation

o Expertise with Hoshin / Business Plan Deployment, target development and

sufficiency planning.

o Manufacturing experience in all areas of automotive production - Press,

Body, Paint, Assembly and Powertrain.

o Driving customer satisfaction programs - J.D.Power, NCBS, warranty

improvement, POE, etc.

o SME for GMS (Global Mfg. System) - Standardization, Built in Quality,

Continuous Improvement, People Involvement and Short Lead Time




JEC Lean Solutions - Lean / CI Consultant

April 2013 - Present

Private Consultant 25+ years expertise in the areas of TPS / LEAN / CI.

Hoshin / Business Plan Deployment, Problem - Solving, PPS, 8D, Red X, TPM /

Equipment Effectiveness / SMED, Process Improvement, Standardization, Gemba

/ Visual Management, 5S, People Development, overall Change Management and



ATC Drivetrain, Oklahoma City, USA

Oct. 2012 -- April 2013

V. P. - Manufacturing Operations Responsible for manufacturing and

overall P & L.($100M+) Led (2) directors and (8) managers across two sites

for transmission and engine production with over 700 indirect employees.

Areas managed included; Engineering, Maintenance, Operations and Safety.

Established Hoshin planning and performance measurement, overall EH & S

program, Genba / visual management, VSM activity and overall Lean

transformation. All KPIs and metrics were improved to levels never achieved

in the company previously. These included; Safety performance, HPU /

productivity, OTD, FPY and EBITDA. Generated substantial improvements in

the areas of engagement, morale and employee satisfaction.


CODA Automotive, Shanghai

Mar. 2011 - April 2012

V.P. - Global Operations Responsible for all manufacturing and quality

activities for CODA - a U.S. - based electric vehicle company. Directed

the program launch at Harbin / Hafei Auto for all electric vehicle

production (Body, Paint, Assembly, Engineering and Supplier Development ),

as well as a lithium battery operation located in Tianjin. Also worked on

established new partnerships with Chinese OEMs for production of new

electric vehicles. Managed a staff of 30 - both foreign and local


Lean Mfg. & Quality Consultant, Shanghai

Sept. 2010 - Mar. 2011

Independent Consultant Working as a quality and manufacturing

efficiency consultant for various China Automotive OEM and Tier One

suppliers. Expertise in the areas of Lean, efficiency and quality

improvement. Also worked with several non - automotive manufacturers of

wind turbines, power tools and electronic products.

EURO - PRO U.S.A., Shenzhen [pic]

2010 - Sept. 2010

V.P. Worldwide Quality Responsible for all aspects of global quality

for the company. This included all operations within China - 14

manufacturing sites of home and kitchen appliances, as well as all US -

based quality personnel. Scope included quality planning, quality

engineering, quality operations, quality assurance, supplier development,

testing and compliance as well as driving change management within the

overall company. Managed a staff of approximately 50 salaried employees

ranging from Sr. Directors to Engineers. Drove change management and

quality - based leadership behaviors across the company.

Developed and executed a product - wide return rate reduction program that

resulted in savings of 10 million USD.


2008 - 2010

Chief Manufacturing & Operations Executive - Asia. Responsible for all

manufacturing and quality operations within the Asia Region - vehicle

production facilities in Beijing, Fuzhou and Taiwan. Also lead the JV

projects between Chrysler and Chery Automotive and Great Wall Motors in

Baoding, China. Included (6) export programs for Chrysler, as well as

overall teaching, coaching and driving Mfg. and Quality system / process

improvements along with lean manufacturing best practices. Established new

business plans and strategies with the Chrysler Asia President for other

business cases and new joint ventures throughout the region. Key member of

the Strategic Council Committee (SCC) reporting directly to the Asia

Pacific CEO. Overall P&L responsibility.


[pic] 2005-2008

Executive Director of Quality - China Operations. Responsible for all

aspects of quality processes and quality improvement activities across all

SGM and GM China Operations, which covers (6) Vehicle Assembly Plants and

(2) Powertrain Manufacturing Facilities. Overall areas of authority and

responsibility include; Driving improvement activities within the

Manufacturing, Supplier Quality and Product Engineering (PATAC)

organizations and ensuring that global processes are being followed.

Leading implementation and improvement of GMAP processes - In-Process /

Delivery Quality, GVDP / GPDP, Product Launch, CPIP process, J.D. Power

improvement planning, warranty and reliablity / durability improvement.

Responsible for driving GM Global and AP Regional quality processes and

initiatives throughout the SGM and SGMW operations. Reduced warranty cost

by 19 million USD.


2000 - 2005

(New plant operation)

Executive Director of Quality & Product Engineering. Responsible for

all aspects of Quality, including; Quality Engineering, Inspection

Operations, Quality Assurance, Supplier Quality, Aftersales Quality and new

program development. Product Engineering responsibilities included; New

program validation, engineering changes / revisions, vehicle development

process, vehicle and part validation and COP / type approval for all

programs - Opel Zafira, Subaru Traviq, Alfa Romeo 156, Isuzu I-190,

Chevrolet C-190 and GMDAT (Daewoo) J-200.



(New Plant Operation)

Executive Director of Quality. Established the Quality Organization for

the largest joint-venture company in China (GM and SAIC). Responsible for

all aspects of Quality, including; Quality Engineering, Quality Planning,

Inspection Operations, Quality Assurance, Supplier Quality and Powertrain

Operations. Helped lead SGM to become the premier operation within General




(New Plant Operation)

Quality Director Director for Quality and Reliability Department and

advisor for the Manufacturing areas of Press, Body, Paint and General

Assembly. Responsible for establishing and managing; Inspection

Operations, Supplier Quality, Quality Engineering and Quality Assurance

sections. Drove the Silao Operation to becoming the top GM Truck production

facility in quality and productivity / cost effectiveness.

TOYOTA MOTOR MFG., U.S.A. Georgetown, Kentucky [pic]


(New Plant Operation)

Assistant Manager, Quality Control. Responsible for quality operation

management and inspection for plastics, stamping, body, paint and assembly

shops as well as for Product Engineering. Managed receiving / inspection,

raw materials and audit lab areas. Supervised and managed a staff of 288

personnel. (1992-1994).

Pilot Project leader. Directed 1992 Sedan model change and new model

introductions of Camry wagon and Coupe, including export projects to Japan,

Europe and Middle-east. (1991-1992)

Group Leader - Functional Inspection. Managed and provided the

leadership to four team leaders and 23 team members in the testing and

inspection of all functional elements. (1991-1992)..

Group Leader - Shipping Quality. Supervised and provided the

leadership to three team leaders and 14 team members in shipping quality

assurance. (1987-1990).

Chevron U.S.A.


Petroleum Geologist [pic]


Bachelor of Science Degree - Chemical Engineering / Geology,


University of Kentucky

Lexington, Kentucky U.S.A.

American Graduate School of International


Business Leadership Program - Thunderbird

Executive Education, 1997

General Motors University - Finance College

Risk Management, 2004

University of Michigan Business School

Executive Education

Strategic Planning and Implementation, 2000

Center for Creative Leadership - Brussels


Leadership Your Perspective 1999

Included complete MBTI, CLI, BENCHMARKS,

behavioral assessments

General Motors University (RenCen campus and

online courses)

Over 150 hours of various

courses...Leadership, Problem-Solving, etc. 1994 - 2007

ORGANIZATIONS American Society for Quality (ASQ)

Quality Manager Certification

- CQ Mgr. 1993 - Current

Society for Industry Leaders

- Standard & Poor's Vista Research

Industry Expert Consultant -

Automotive Sector


Available upon request

Contact this candidate