Quality Manager
Resume:
Robert J. Begg **** Bayberry Circle
North Olmsted, Ohio 44070
****@**********.***
December 2018
Dear Hiring Executive:
Please accept this letter as my expressed interest in joining your organization as your Quality Manager. The enclosed resume will provide you with a brief outline of my skills and accomplishments and job experiences. In summary they include:
Cultivated senior management leadership, manufacturing and quality expertise in high volume, close tolerance operations through 20+ years of experience in areas of senior staff, operations, quality systems design, development and maintenance; employee training; process engineering; project management; application of appropriate statistical methodologies; supplier development, quality and performance improvement; Lean Manufacturing and Visual Management; and, continual improvement.
Highly experienced in organizational quality management systems revitalizations, turn-arounds and improvement through focusing on value from the customer needs, expectations and perceptions; processes, process variation, process controls and standardization; application of organization-wide visual management tools and practices; real-time, in-gemba problem solving by “stopping work so work never has to stop”; improvement and change sustainment through process validation, process audits, LPA’s and Gemba Walks; and, choosing and monitoring the right measurables to track success. This also includes Quality Department reorganizations and refocusing of their efforts on the critical few through retraining and auditing versus inspection.
Multi-site experience / extensive national and international travel experience
Certified Lean Six Sigma Black Belt (Kent State) & Six Sigma Green Belt (Allied-Signal) / Certified Lean Trainer (Ford LRC) / Certified Trainer the Trainer, Trainer (Neumayer-Tekfor Academy) / Certified ISO 9001 Lead Assessor (Hadley Walker) / certified Quality System Basics trainer (General Motors)
Highly proactive in initiating and leading changes to enhance profitability and customer satisfaction; design, development and implementation of ISO 9000: 2015 & 2008 and TS 16949 Quality Management Systems. Developed and implemented the highly successful “Go-to-Gemba” continual improvement and corrective action process.
Extensive quality management system development, implementation and sustainability experience across multiple industries, as an OEM and contract manufacturer, including automotive (16+ years), on-road material handling, medical, power distribution equipment, commercial and consumer lawn care equipment, electronic equipment enclosures, sheet and heavy metal fabrications, cold and hot forging, rubber extrusion, ceramic pressure molding, fasteners and product final assembly.
Given the combination of these factors, I am confident I would quickly become a valued and a key contributing member of your team, helping your organization in meeting its goals and objectives through improved customer satisfaction and profitability. Thank you for your consideration. Should you have any additional questions prior to a personal interview, I can be reached at 440-***-****.
Most sincerely,
Robert J Begg
Robert J. Begg 7132 Bayberry Circle
North Olmsted, Ohio 44070
****@**********.***
Quality and Manufacturing Operations Professional
Accomplished, proactive, hands-on Quality and Manufacturing Professional, Certified Lean Six Sigma Black Belt and Certified Lean Manufacturing Trainer, seeking to apply a variety of proven skills, expertise and talents towards a new challenge. Possess a unique combination of leadership, communication and technical skills. Expertise includes:
ISO 9001: 2008 & 2015 / TS 16949 / Quality Management System Design & Development
Six Sigma Methodologies
Supplier Development & Supplier Quality
New Product Launches / APQP & PPAP
Lean Manufacturing / Visual Management & Visual Controls Development and Implementation / Work Standardization
Root Cause Analysis (3L5W, C&E) / Problem Solving (PDAC, 8D, DMAIC) / Continual Improvement & Kaizen
Project Management
Personnel & Leadership Development / Mentoring
Employee Training / Training Program Development
Internal process & product audits / Internal QMS Audits / LPA’s / Gemba Walks / 3rd Party Audits
Quality systems process controls design, development, implementation & validation
Professional Experience
WALTOC LIFT CORPORATION, 2015 – Present (Tallmadge, Ohio)
Quality Manager (OEM lift gate designer, assembler)
Staff and overall responsibilities for quality management system for a $100+M OEM provider of truck mounted lift gates for on-road material handling. Responsible for the full development, implementation and sustainment of an ISO 9001: 2015 quality management system including supplier quality program and requirements. Lead a department of 3 staff and 4 quality technicians.
Designed and developed supplier quality system requirements that includes: initial on-site assessments by high level management team; QMS audits by Quality Manager and SQE; supplier improvement program with established goals for all key suppliers and a monthly supplier scorecard, step-down chart that resulted in an over 50% overall improvement in supplier measurables; implemented a supplier APQP – PPAP requirements and process; provided key, underperforming supplier with on-site problem solving training, APQP- PFMEA-PPAP training and fundamental Lean Manufacturing Training.
The supplier quality program included the development and presentation of an annual, off-site supplier quality conference for 50+ key suppliers.
Developed and implemented a rapid response for quality process based on the GM Quality Systems Basic Fast Response process.
Implemented a “go-to-gemba” 5 WHY Problem Solving Process for use in work cell by operations leadership, the involved assembler and quality technician. Included development of the training program for this process all operations leadership and entire Quality Department. Improvement lead to a 1st time right (FTR/FTT) quality improvements by reducing repeat issues and achieving a FTR/FTT of 99.93%.
Identified largest customer satisfaction issue through “deep-dive data analysis. Developed an improvement program following 4DX Process that involved launching multiple improvement teams. Reduced incidents by over 90%.
IAC, 2014 (Dayton, Tennessee), October –December 2014
Consultant (OEM automotive finished interior manufacturer – GM Corvette, Nissan)
Client was an OEM automotive parts supplier who was the sole producer of finished interior components for the General Motors flagship vehicle, the Corvette. Brought in to assist client in preparing for and successfully passing their GM Quality Systems Basic audit including the development of a visual management process to assist in increasing span of control for floor supervision due to an operational process expansion.
Successfully developed, implemented and provided all the training for the Drill-wide, Drill-deep Process for the client’s entire leadership team on all 3 shifts.
Successfully developed and implemented a combined 5S and TPM program for the all the assembly processes/cells. Sustainability tools totally based on and implemented fully utilizing only visual controls and visual management techniques and tools. Implementation of this program increased up-time, increased supervisor effectiveness and named by GM as a new “best-in-class” approach after the client successfully passed their audit.
Developed and implemented a PM program for all assembly and checking fixtures, again, utilizing visual a management tools to alert supervision to non-standard conditions.
PARKOHIO PRODUCTS, 2013 – April 2014 (Cleveland, Ohio)
Quality Manager (Tier 1 and 2 automotive parts supplier – rubber injection molding)
Staff and overall Quality Management Systems accountability for a $22M injection rubber molder of anti-vibration, EDS protection and dust control. Lead a department of 9 full-time product quality auditors and 7 full-time inspectors.
Development and implemented a new “project management style” APQP process to help ensure improved launches of new products by reducing potential issues and problems that had been being over-looked in the previous APQP process.
Developed and implemented a Production Readiness Review process to verify new processes were functioning as designed and expected and that the outputs are and would be able to consistently meet customer expectations.
Revised the Layered Audit Process to focus more on adherence to process parameters, correct demolding, deflashing and inspection of product. The new LPA’s will require the auditor to review the video tape of the process they are going to audit using the approved standardized work and then auditing the process based on that adherence to that standardized work
Developed a 50 point Quality Improvement Program for 2014 which focuses on doing the simple things correctly, building in visual management tools into the process to alert shift supervisors when processes may not be meeting requirements and redesigned deflashing-inspection stations that will dramatically improve the work cell cleanliness and organization at each injection press
Developing and implementing standardized work for each part number which will also include the correct methodologies for the entire injection molding process including inspection of parts by the press operators as they are being deflashed.
RAMCO SPECIALTIES, INC., 2012 – 2013 (Hudson, Ohio)
Director of Quality (Tier 1and 2 automotive parts supplier – fasteners, distributor. Largest supplier of prevailing toque lock nuts in the world. Operated out of 3 separate facilities)
Staff and overall Quality Management Systems and Supplier Quality accountability for a $50M fastener distributor with limited value-added operations as a tier 1 & 2 automotive supplier. Lead a department of 5 full-time staff and 5 technicians that includes two Quality Engineers and one, Supplier Quality Engineer.
Implemented a monthly, comprehensive management review process
Developed and implemented a comprehensive APQP and PPAP process that reduced time to complete a PPAP submission from 4-8 hours to 1-2 hours max. Accomplished through creation and utilized generic, process-specific APQP documentation, annual gauge R&R studies, continual product torque test values and evaluations, annual certifications, on-going process capability data and test results from suppliers on their process and products.
Developed a supplier development and control process including a Supplier Purchasing Manual, a Supplier Quality Manual and a Supplier Quality Engineer position
Implemented a “GM Fast Response” Customer Complaint and Rejection process that resulted in faster and improved corrective action responses to customer issues
Revised and updated entire quality management system, including a completely new quality manual
Flow modeled all upper level internal processes to be used as tools in training new employees and corrective actions as well as in gemba work instructions
Successfully revised an extremely complex and lengthy incoming material process audit that reduced audit times by over 50% by prescriptively defining every requirement of the process from sample sizes, to product characteristics to be checked to requirement for the measurement tools to be used and records to be maintained by automatic input of measurements into an electronic record. Re-evaluated semi-annually to determine if process was effective and if samples sizes were adequate or could be reduced based on data.
TEKFOR USA, Neumayer- Tekfor Group, 2007 – 2012 (Wooster, Ohio)
Manager, Quality Systems (Tier 1 and 2 automotive parts supplier for drive train gears, engine components and wheel hubs– hot and cold forging and high precision machining, broaching, tapping and balancing)
Staff and overall Quality Management Systems accountability for a $90+M custom, high volume OEM hot forging & precision machining tier 1 & 2 automotive supplier. Directed a department of 20 full-time employees on three shifts including a staff that includes a Six Sigma Black Belt, Quality Engineers, Metallurgical Lab Supervisor, Quality Department Supervisor and a full-time Gauge Technician. Highlights include:
Reduction of internal manufacturing waste by 50%, saving the company over $100k/month
Reduction in cost of poor quality by 26% in 1 year for over a $300,000 savings
Rebuilding and restructuring of Quality Department in order to make it more pro-actively directed and customer focused
Reduction in customer rejections from over 70,000 PPM to 30 PPM
Achieve Certified Trainer the Trainer status
Developed, implemented and lead “Go-to-Gemba” corrective action and continual improvement program
Reduced response time for completion of corrective action responses from an average of 113 days to under 15 days
Developed and implemented an extensive and comprehensive new hire and new machine operator training program
Developed and implemented SPC training program, “Hitting the Target”
Successful PPAP and launch of 130+ new part numbers in 14 months
Implemented a comprehensive monthly management review process
Successfully implemented layered process audit program
Developed and implemented Lean Leader Standard Work
Complete revision and upgrade of internal quality management system reducing procedures, work instruction and documentation by over 75% resulting in a “0” finding TS 16949 recertification audit in 2009
ARTISAN INDUSTRIES, INC., 2006 – May, 2007 (Streetsboro & Cleveland, Ohio)
Manager, Quality Systems (Contract sheet metal and heavy fabricator - laser, press brake, welding, assembly)
Staff and overall Quality Management Systems accountability for a $20M custom OEM sheet metal fabricator and metal stampings manufacturer. Directed a department of 5 employees including 2 Quality Engineers, operating in two separate facilities. Highlights include:
Developed a new quality management system resulting in an overall reduction of systems documentation by 60%
Developed “Management, Supervisory and Leadership Development Program”
Established of internal quality system metrics and measurables
Developed comprehensive monthly quality and business management review process
PCC AIRFOILS, LLC – CERAMICS GROUP, 2004 to 2006 (Wickliffe & Cleveland, Ohio; Sanford, North Carolina)
Manager, Quality Systems (not for profit work center, OEM supplier of custom airfoil ceramic cores to supply directly to PCC Airfoils 3 Ohio foundries)
Staff and overall Quality Management Systems accountability for a $26M ceramic core OEM manufacturer to the aerospace and land-based turbine industries. Continual Improvement Champion. Lead a department of 8 employees operating within 4 separate facilities including 2 Quality Engineers.
Highlights include:
Multi-site leadership of quality functions
Developed and implemented video training for LPS finishing operations to reduce variation in finishing techniques and decrease overall training time.
Developed and implemented a manual, operator based poka-yoke system in LPS finishing operations that reduced customer rejections by over 5%
Developed and integrated an electronic-based customer complaint and rejection “instant notification” system
Established continual improvement process that included training of senior staff, Quality Department and manufacturing line supervision in various improvement methodologies.
Met weekly on-site with the 3 foundries to review quality issues and provide corrective action responses
ITW ANCHOR FASTENERS, 2001 to 2004 (Bedford Heights, Ohio)
Director of Quality & Continuous Improvement (Tier 1 and 2 automotive fastener supplier – cold heading, thread rolling, induction hardening)
Staff and Quality Management Systems accountability for $34M cold-headed fasteners TS 16949 registered, OEM Tier 1 and 2 manufacturer to the automotive industry. Lead a department of 10 employees including a Quality Assurance Manager, Quality Engineer and accredited laboratory technicians and inspectors. Highlights:
Reduced OEM quality metrics, PPM and customer concerns, by over 75%. For 2004, achieved an overall OEM 2 PPM level (shipping 60+ million parts/month)
Increased on-time PPAP submission from 15% to 98%, reduced PPAP rejections to “0”
Increased through-put in Final Inspection and Test operations by over 60% through targeted inspections based on process capability data and final inspection data.
Overall improvements in overall product quality and delivery lead to an over 40% company growth through awarding of new contracts.
Developed 8D root cause analysis and corrective action procedure that was named a division “ITW Best Practice”.
Lead overall continuous improvement program. Focus on 5S, poka-yoke, visual factory, waste reduction, materials flow and plant layout, key measurables. Developed internal “5S +1” process which was named as an ITW Best Practice
Named as the “benchmark division” by General Motors for use of the new General Motors “Shop Floor Excellence” and “Quality Systems Basics” requirements
Named GM Supplier of the Year, 2003
Daimler-Chrysler PentaStar winner, 2003
Awarded Ford Q1 status after initial on-site audit
E&W SERVICES, INC. Mentor and Willoughby, Ohio
(Contract heavy metal and sheet metal fabricator: CNC punching, CNC laser, stamping, press brake, welding: MIG-TIG – stick-resistance, machining, EDM, PEM installation, screw machining, in-house painting (wet and power coat), in-house zinc and nickel plating, in-house silk screening, in-house assembly and kitting, custom packaging)
Director, Quality Systems, Electro-Plating and Process Engineering
Project Manager, ITG Enclosure Program
Additional work experience available upon request.
Education
BOWLING GREEN STATE UNIVERSITY, Bowling Green, Ohio
B.S., Journalism, Minors in International Law and Contemporary & Ancient Art History
CUYAHOGA COMMUNITY COLLEGE, Parma, Ohio
Business Management and Organizational Leadership
Extensive continued education including: over 200 hours of Six Sigma training; ISO 9000 / TS 16949 training through AIAG; over 64 hours training in Lean Manufacturing through Ford LRC; ISO Lead Assessor Certification; Statistical Process Control; 40 hours of ISO 9001: 2015 training through BSI
Independent Training and Certifications
ISO Lead Assessor
ISO 9001/TS 16949
Six Sigma Green Belt
Lean Six Sigma Black Belt
Certified Lean Trainer
Certified Train the Trainer, Trainer
ISO 9001: 2015
Software Competencies
MS Office
MS Visio
Google Suite: Google Drive, Google Docs, Google Sheets, Google Slides, Google Hangout
Minitab
Quality Companion
Q1 Macros for Excel
Plexus ERP
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