Quality Assurance Manager
Resume:
MERRILL SMITH
Helena, AL
Summary of Qualifications
Extensive experience in Quality Assurance and Manufacturing, most in the
automotive industry. Six-Sigma Green Belt trained in Kaizen, BBP (Best
Business Practice), Lean Manufacturing and One-Piece flow. Proven ability
to reduce internal / external PPM and costs while improving efficiency and
productivity. Excellent ability to develop working teams to achieve goals
within established timeframes. Significant experience dealing with
customers to improve overall relations.
PROFESSIONAL EXPERIENCE
QUALITY MANAGER / ENVIROMENTAL & SAFETY MANAGER
2010 - Present
Eissmann Automotive- Pell City, AL (Automotive - Leather/Vinyl wrapping
of O.E.M. parts)
. Reduced reject cases at customer from 78 in 2009 to 4 in 2011 and
2012
. Decreased scrap from customer returns by 80%
. Reduced TS-1694 audit findings from 10 down to one in 2010. 2011
& 2012 audits had 3 each
. Responsible for monthly Key Measurables report provided to
corporate office
QUALITY ENGINEER 2010
(Contract position)
Brose - Vance, AL (Automotive - Door System Assembly / Automotive
Assembly)
. Assisted Quality Team with systems installation for incoming
inspection
. Developed Layered Process Audit system for Management / Staff
. Root Caused and provided solution for largest internal reject
item.
OPERATIONS MANAGER 2007 -
2009
CONTINUOUS IMPROVEMENT / LAUNCH MANAGER
Plastech- McCalla, AL (Automotive - Injection molding and assembly)
Johnson Controls Interior Manufacturing
. Reduced past due parts from 200,000 pcs to 30,000 pcs in 4 months.
Eliminated all past dues in 6 months.
. Responsible for plant cost saving goals from Lean Manufacturing /
Kaizen projects of $3.5 million/year.
. Improved plant schedule attainment from 50% to over 70%.
. Managed increase in plant headcount from 74 direct operators to
168 due to increase in business
. Decreased O.T. due to increased efficiency and O.E.E. improvements
. Transferred and launched 170 current production GM tools within 90
days
. Improved production reporting accuracy to reduce quarterly
inventory variances from $300.000 to $15,000
. Responsible for transferring 4 Honda door assembly lines from JCI
- Canada
QUALITY ASSURANCE MANAGER 2006 -
2007
Burner Systems International - Chattanooga, TN (Appliance - Gas supply
tubing)
. Reduced external corrective actions from 77 to 8 in five months by
involving a team approach
. Plant PPM reduced by over 60% in 13 months
. On-site support for the two largest customers on a weekly basis
resulting in improved customer satisfaction
. Lead QA Manager for three plants in North America
OPERATIONS / LAUNCH MANAGER
2003 - 2006
Plastech Engineered Products - McCalla, AL (Automotive - Injection
molding and assembly)
. Launched startup of green site manufacturing facility including plant
layout, material flow, equipment installation and floor operations for
50 presses and assembly operations.
. Managed day-to-day plant operations including daily production,
scheduling, inventory control, engineering layouts / changes, tooling,
labor and daily financials.
. Established best business practices for production reporting and
performed initial training for all new hires during orientation.
. Established and implemented quality assurance processes and standard
operation procedures including PPAP, FMEA, Control Plans, Inspection
Instructions, and Operator Instruction.
. Launched 4 new programs with over 250 tools for end users including
Mercedes, GM, and Hyundai
. Filled in for Plant Manager during absences from the plant including
daily updates to owner of company focusing on daily financials,
production quotas, delivery, and customer satisfaction
.
Merrill Smith - page 2
QUALITY ASSURANCE MANAGER 1996 -
2003
Lear Corporation - Dayton, TN (Automotive - Injection molding and
assembly)
. QS-9000 / TS16949 & ISO14001 Trained Internal Auditor
. Six Sigma - Greenbelt certified
. Planned / Implemented efforts to achieve QS9000 & ISO14001
Certification
. Assisted in launch of $36 million new door line program (doubling size
of business)
. PPM reduction over last three years - from 56 PPM to 11 PPM on 12
million pieces shipped
. Responsible for cost recovery program for Incoming Inspection that
netted $150,000 annually
SENIOR QUALITY ENGINEER
1994 - 1996
Lear Corporation (United Technologies Automotive) - Dayton, TN
. Responsible for all Ford warranty evaluations
. Involved in all aspects of launch of 3 new programs and transfer of 3
other programs
. Investigation and resolution of customer field issues
. Wrote control plans, FMEAs, and annual validation tests for programs
QUALITY ASSURANCE DIRECTOR
1992 - 1994
Creative Plastic Molders - Lexington, N.C. (Custom - Injection molding and
assembly)
K & K Plastics - Ayden, N.C.
. Administered overall quality systems at two manufacturing plants
. Directed preparation of customer surveys for companies including Black
& Decker,
PPG and, Hallmark
. Established standardized quality criteria through direct customer
contact
. Implemented and trained employees for an SPC program at both plants
QUALITY ASSURANCE MANAGER 1989 -1992
Nyloncraft - Hickory, N.C. (Automotive - Injection molding)
. Achieved Ford Q1 Award in 3 months time
. Received "Excellent" rating from customers including TRW, Bosch Power
Tool, Bosch Automotive, Excel Industries and, Saginaw Steering
. Established Quality Operating System (QOS) per Ford guidelines
QUALITY ASSURANCE ENGINEER 1987
- 1989
Applied Composites - Hartford City, IN (Automotive - Compression
molding and Paint)
. Interim Quality Assurance Manager
. Liaison between company and General Motors
. Responsible for quality system rated "Excellent" in GM and Chrysler
supplier audits
. Wrote lab manual for a GM-certified laboratory
. Scheduled and conducted all new vendor audits
EDUCATION
Studied toward: Bachelor of Science in Industrial Management / Industrial
Engineering (IMIE), Purdue University, West Lafayette, IN
SPECIAL TRAINING
Lead Internal Auditor for QS-9000, TS-16949, ISO14000
Six Sigma - Greenbelt
Lean Manufacturing / Kaizen / O.E.E.
Design of Experiments (DOE) of Taguchi Methods
Customer Problem Solving Techniques - Ford and Chrysler
Operation and programming of Brown & Sharp, and Mitutoyo CMM software
Contact this candidate