Manager Quality

Philip Calhoun

VP Operations - TOTAL QUALITY ENGINEERING

Farmington Hills, MI 48331

ac0mtk@r.postjobfree.com - 248-***-****

FORD MOTOR COMPANY- DIRECTOR MANUFACTURING QUALITY (2007-2011)

• Successfully reduced CPU 27%, overall warranty R/1000 30%, and TGW (Things Gone Wrong) by 40% that increased the number of FLM recommendations in Consumer Reports Magazine.

• Implemented the Quality Operating System in South America.

• Won four out of ten segments in the JD Power Initial Quality survey.

• Reduced component parts per million (PPM) by 42%

• Reduced warranty spend and cost by seven (7) million dollars FORD MOTOR COMPANY- WIXOM PLANT MANAGER (2006-2007)

• Promoted a safety culture that strengthened effectiveness and improved performance by 40%.

• Strategized a transition/idle plan for the plants decommission, ensuring ongoing safety, cost, quality, environmental factors with a focus on maintaining employee morale.

• Coordinated with precision the relocation of tools/facilities that led to ongoing production of the Lincoln Town Car with no volume loss.

• Directed capacity planning for shift reduction and smooth relocation of more than 2,000 employees.

• Recipient of the J.D. Power Platinum Award for top plant in the world in quality. FORD MOTOR COMPANY- CHICAGO ASSEMBLY LEAN MANUFACTURING MANAGER (2002-2004)

• Awarded the SHINGO Prize for successful Lean Implementation and practices. FORD MOTOR COMPANY - ATLANTA ASSEMBLY BODY SHOP MANAGER (2001-2003)

• Incorporated Dimensional Strategy best practices that were adopted enterprise-wide.

• JD Power Bronze Award Winner for initial quality. FORD MOTOR COMPANY - OAKVILLE, CANADA- FINAL AREA MANAGER (2000-2000) Corporate Diversity Award Winner and Safety Award honoree Willing to relocate: Anywhere

Authorized to work in the US for any employer

WORK EXPERIENCE

QUALITY DIRECTOR

TOTAL QUALITY ENGINEERING - Farmington Hills, MI - 2015 - Present Consults high performance, while effectively developing/promoting company key messages across safety, cost, quality, engineering and delivery in every role. Ability to convince leadership to agree upon operating principles and standards with a continuous improvement mindset.

• Developed quality operating system for electrical vehicle build process at 2 OEMs

• Developed Vehicle Personalization Centers (VPC) in Manufacturing Facilities

• Reduced defect escapes and improved FTT by 30%

SITE MANAGER

FORD MOTOR COMPANY - Wayne, MI - 2013 - 2015

Directed 5 plant site with 7,000 Ford Salaried/UAW and Suppliers

• Launched Ford Focus and Ford C-MAX

• Developed Product Kitting that improved Safety, Quality and Productivity

• Reduced product warranty by 47% and cost per unit by $8 dollars.

• Reduced mis-builds from 117 PPM to 1 PPM

• Improved employee Pulse scores from 42% to 82%

• Hosted Presidential visit

FORD MOTOR COMPANY- SITE MANAGER, DEARBORN ENGINE PLANT/WOODHAVEN FORGE - DEARBORN, MI (2011-213)

• Launched 2.0 direct injection TiVCT program, won Presidents Quality Award for best engine plant

• Launched 4 crew

• Won the Presidents Quality Award for the #1 Plant in Quality

• Improved Employee Pulse scores from 53% to 79%

DIRECTOR MANUFACTURING QUALITY

FORD MOTOR COMPANY - Dearborn, MI - 2007 - 2011

In charge of the quality operating systems for all 35 stamping/assembly/powertrain manufacturing facilities across North, South and Central America, staying abreast of all federal regulations.

• Monitors performance in product development and new model launches; designed bailment strategies

• Developed Global Sticker Review process

• Championed World Class Manufacturing Quality Pillar

• Developed Global Ford Customer Product acceptance (GFCPA) Standard

• Developed Global Six Sigma Training process

• Successfully negotiated 3 National Contracts with the UAW as the sub council lead.

• Developed Training Certification for Quality Representative and Quality engineers.

• Developed Global Launch Gate ways for New Model Programs

• Developed Global Port QOS

PLANT MANAGER

FORD MOTOR COMPANY - Wixom, MI - 2006 - 2007

Directed the activities of 2,500 UAW employees at the company's largest Lincoln manufacturing plant.

• JD Power Platinum Award Winner

ASSISTANT PLANT MANAGER

FORD MOTOR COMPANY - Kansas City, MO - 2004 - 2006 Introduced Lean manufacturing principles that improved service in engineering, safety and quality.

• Led 6,000 UAW employees, and controlled a $450M budget during the launch of the Ford F-150.

• JD Power Segment Winner

LEAN MANUFACTURING MANAGER

FORD MOTOR COMPANY - Chicago, IL - 2002 - 2004

Managed 3,100 UAW employees for launch of the Ford 500, Freestyle, and Mercury Montego.

• Led the successful and on-time installation of the first Flexible Body Shop.

• JD Power Bronze Winner

BODY SHOP MANAGER

FORD MOTOR COMPANY - Atlanta, GA - 2001 - 2003

In charge of 600 UAW employees in the manufacturing, engineering, and maintenance of completed sheet metal body structures ready for assembly.

FINAL AREA MANAGER, ONTARIO, CANADA

FORD MOTOR COMPANY - 2000 - 2001

Led 750 CAW employees during manufacturing, engineering, and maintenance of the final assembly of the Ford F-150-SVT and F-150 Harley Davidson vehicles. BODY AREA MANAGER, ONTARIO, CANADA

FORD MOTOR COMPANY - 1999 - 2000

Provided leadership to 425 CAW employees during the construction of the new body facility plant in preparation for the launch of the F-150 Harley Davidson vehicle. Stamping Quality Manager

FORD MOTOR COMPANY - Dearborn, MI - 1992 - 1999

• Tool and Die Section Leader

• Press Room Maintenance Supervisor

• Plant Engineering Supervisor

• Injection Mold Supervisor

Shift Manager

FRITO LAY - Allen Park, MI - 1990 - 1992

• Led a team of 120 hourly associates producing various salty snacks on 3 production lines

• Meet service to sales daily production targets

• Performed OHSA, USDA and FDA cGMP compliance Audit EDUCATION

MBA in Finance

New York University - New York, NY

Economics

London School of Economics - London, UK

Lean Manufacturing Management

DePaul University - Chicago, IL

Mechanical Engineering

University of Michigan - Ann Arbor, MI

SKILLS

PROCESS IMPROVEMENTS, PROJECT MANAGEMENT, STRATEGIC PLANNING, Manufacturing, World Class Manufacturing, Toyota Production Sysytem, Financial Management, People Management, Supply Chain Management, Supplier Management

CERTIFICATIONS/LICENSES

Certified Six Sigma Black Belt

2014-08 - Present

Certified Lean Sigma

2015-01 - Present

ADDITIONAL INFORMATION

AREAS OF EXPERTISE

Lean Sigma •Cost Reductions • Engineering • Issue Resolution • Process Improvements Project Management • Quality Excellence • Safety • Strategic Planning • Team Leadership

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