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Quality Engineer Injection Molding

Carleton, Michigan, 48117, United States
April 09, 2018

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Amy M. Dobberstein

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

Monroe Michigan, 48162



Masters Engineering Mgt., Quality & Lean; Lead Auditor IATF/TS; Bachelors Manufacturing Engineering Technology, USAF Electrician and HVAC Technician (veteran).

23 years of experience in Quality, Manufacturing, Engineering, Auditing and Technical Operations

ALWAYS striving to exceed the Customers’ Expectations per the Voice of the Customer. Utilizes, develops or improves Quality Operating Systems to reach S.M.A.R.T goals, repeatable, value added processes ensuring positive dashboard metrics for the company’s strategic initiatives.

Reaches best result in all endeavors while consistently maintaining exemplary standards.

Armed with positive, professional, value added and safe judgment facilitating sound application of proper technical directives, policies and regulations (CSRs, IATF, ISO, ASQ, Injection molding, Stamping and Assembly; CCs, SCs, Key & Customer Characteristics). Multiple shift production facilities.

Partner 250 acre grain farm converting from conventional to organic 2019 to 2020.


QUALITY OPERATING SYSTEMS MGR & QE - Ammex Plastics (Echo) NOVEMBER 2013 – March 2018

Development, implementation & continuous improvement of QOS & MOS standards, including Project, Part & Process development, training and audits to include Customer & PPAP Launch, IATF, TS, ISO, Lean, etc).

Managed all 22 customers and 9 suppliers for the Quality Operating System Requirements to include: NC’s, SCARs, QAs, Research analysis, PPAPs (Levels 1 – 5 and annuals), Audits, Launches, etc. for the 300 + PN’s across 39 million parts shipped annually. Completed initial feedback through root cause, corrective action and validation of the CAs ensuring customer satisfaction. Reduced External PPM from 3 to under 2 in 12 months for over 3 years maintaining below 1 PPM over last 9 months.

Development, implementation & risk assessments of all Core Operating Processes (COPs) and Secondary Operating Processes (SOPs) to drive the Quality Manual & Quality Policy. KPIs dedicated continuously to improve the directed company tactical and strategic initiative.

Managed over all TS / IATF compliance requirements, example: Management Review, Internal Audit, Clauses 5 - 10 . Developed, implemented and or improved processes and procedures to insure compliance to the Customer, External & Internal Compliances & regulatory clauses. Improved Company 3rd party audit results from 1 Major each audit to 4 out of 4 TS Audits with 0 major Non-Conformances & the IATF gap audit completed.

Quality Staff Department Development: Org chart QT Lead add, all Quality Job Descriptions, training and technical development (MSA’s, R&R, SCs, Caliper, Micrometer, Smart Scope, GD&T gauging, Print proficiency) increasing Quality staff from 6 to 15 team members due to sales $ increases of > 8% RFQ hit rates year over year (part volume flat lined, Increased: part & mold difficulty & part size). Injection Molding Press increases from 9 to 24 to include 4 assembly 5S cells.

Implementation of the Maintenance Operating System (MOS) and Mold Maintenance Operating System (MMOS) compliance projects. Company realized reduction of scrap %, production down time and repeat customer failures.

Implementation of First Piece Check & retention, value added part conveyance to included conveyors and pass through gauging from batch & 100% inspection per tote pull, flash light check (hidden areas), gauging. Reduction of non-value added QT labor, production scrap %s and Sorting %s realized. Increased customer satisfaction & External COPQ.

Implementation of Equipment Set Up Department. Moving 22 jobs from offline to online and all new jobs launched & PPAPed on-line with back off line option ensuring customer ON-TIME delivery and compliant processes. Project included: Standard Operating Procedures, Org Chart addition, Lead Set up and all training.

Implementation of Calibration Cost Saving & Production Disturbance to flow Project. Implemented “ON-SITE” 2 day calibration with new 17025 Calibration house. Reduced Technician annual labor by $1500 and production down time (zero gauges removed from the floor).


Corporate Quality Engineer for 8 manufacturing facilities. Including all Corporate and Supplier Quality Concerns. 8D, 5why, 7 step, A3, Kaizen and associated methodologies used for Mechanism, Poly, and Frame both Motion and Stationary production assembly lines. 24 hour QA, Quarantine, Sort & Containment consistently achieved. Improved processes / product through all RCCAs and 100% QA closures achieved.

Corporate Quality Warranty Reduction Engineer - Poly & Foam. Goal Increase customer satisfaction and reduce warranty $ and failure rates across Motion and stationary product: seat, back, arm. Annual Warranty Poly & Foam $1.3 million ppm 10523. Project resulted in a reduction of 1000 warranty claims from FY11 – FY12 Chaise & Seat.

Co-Team Development, Instruction and Audits of Formal Quality Practices ie: PFMEA, Control Plan, Value Stream Mapping, COPQ, 5S, Kaizen, RCCA, PDCA, Layered Process Audits, etc. 25 Train the trainer courses completed across the 8 facilities. Training Materials distributed, controlled and updated into the division audits. Project ensured repeatable processes and procedures across the Corporation.

Development Team member for the Plant Certified Quality Associate Program Levels I & II.

Division Project, Process and Product PM & Auditor: Layered Process Audits, Out of Box Product Audits, Bi-Annual Furniture Market Setup & Audits to improve customer satisfaction and reduce warranty $.

SR. QUALITY ENGINEER – Johnson Controls, Inc. JANUARY 2003 – JUNE 2005

Sr. Quality Engineer for the Lincoln LS front and rear row seating assembly lines.

Supervised 4 Quality Technicians daily tasks, audits, processes, etc.

Analyzed Leather and Plastic manufacturing and processing to ensure highest quality.

Ford Wixom assembly on site QE, daily quality report out for customer concerns through closure.

8D response leader, monthly continuous improvement metric and concern closure lead.

6 panel monthly report out lead Wixom Assembly for cost and customer improvements.

Vehicle Reduction Team member resulting in decreased warranty share costs.

JD-Power monthly warranty analysis and report out to Ford Management.

PFEMA, control plans, work instructions, and process flow chart development and implementation.

SPC Charting, R&R and Process Capability Studies to validate production and quality.


Supervising, Training and Scheduling 23 Operators on the Torque Converter Assembly lines.

Consistently meeting production requirements by training operators on quality assembly tasks.

Maintenance trouble shooting and repair with job setters to minimize down time for such operations as: Honing, Precision grinding, Welding and all aspects of Torque Converter assembly.

QUALITY ENGINEER- Dana Corporation 1999 - MAY 2002

Successfully PPAPed 82 Brake assemblies for 3 new OEM customers in six months resulting in DOUBLED production volumes and Lead Brake center for DANA

Tier 1 supplier to DaimlerChrysler, Ford, Harley-Davidson, Coni-teves, Tower, etc

Six Sigma Black Belt, Lean Manufacturing, Kaizen – blitz and Root Cause Analysis

Quality Lab Team Leader, leading floor auditors with daily problem solving and manpower utilization

Team Leader for Quality manual generation all quality sections: lab, measurement, calibration, layout, R&r, Process Capability, Ppap’s, control plans and work instructions.

Managed retention and warranty warehouse for customers 7-year retention requirements.

Utilized 8D problem solving and 7-step analysis to request and write SCARs and CARs.

Design Reviews, manufacturing feasibility analysis and Customer approval presentations.

SPC Charting, R&R and Process Capability Studies to validate production and quality.

QS and ISO coordinator and trainer pursuing Certified Quality Engineering certification.

DFEMA, PFEMA, control plans, work instructions, and process flow chart generation.

Analysis and presentation of performance testing for new, annual and warranty designs

Performed CMM & Vector Machine operations validating GD&T and linear dimensions.


Technician 2nd and 3rd shifts, extreme deployments over in a 14-aircraft maintenance unit insuring 100% take off rates.

Isolated faults, repaired, modified, and troubleshot and inspected aircraft systems.

Lockheed and Raytheon Eng.Team Member in writing technical operating instructions.


Eastern Michigan University December 2011

Graduate: Masters of Science – Engineering Management, Quality & Lean Principles

University of West Florida, Pensacola Florida April 2002

Graduate: B.S. – Manufacturing Engineering Technology

Minor – Chemistry/ Materials Science

Community College of the Air Force Technical Institute December 1995

Certificate: Electrical and HVAC Journeyman

University of Toledo, Toledo Ohio September 1991-1995

Major: Chemical Engineering 130 Quarter Hours

Professional Training & Seminars

IATF 16949 AIAG / Exemplar Global Lead Auditor Certification January 2018

Lean Enterprise Institute Member (LEI Current – December 2011

Project Management, Kepner -Tregoe (KT) Project Management Methodology, LZB…….August 23-25, 2005

Six Sigma Black Belt Certification, Dana University January 28 – May 10, 2002

Process Mapping, WIP control, Dana University June 13-15, 2002

Internal Auditor of Quality Systems to QS9000 & ISO 10011-1 January 22-24, 2002

American Society of Quality Member (ASQ Current - 20002


Ammex Plastics Quality Manager Promotion January 2015

La-Z-Boy Manufacturing - VP Selected - Professional Achievement Award, $5K LZB Stock October 2013

Outstanding Department Award, 82 Successful PPAPs, promoted to Sr. Quality Engineer March 2002

Honor Graduate, 3.44 GPA, University of West Florida May 2001

Air Force Achievement Metal, 1st & 2nd oak leaf cluster, Meritorious Service 1996-97 & 1997-99

Airman of the Year, 437th Air Generation Squadron

Superb Technical performance, exemplary attitude and ambition on and off duty 1996

Diamond Sharp Award, Exceptional performance, professionalism and outstanding Appearance 1996

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