MICHAEL A. ZERNICK

*** ******* **. 608-***-****

Oregon, WI 53575 ac55z2@r.postjobfree.com

Qualifications Summary

A Quality and Continuous Improvement Manager who has worked in multiple industries with many successes.

Worked as a contracted Quality Engineer with Lear Seating Company in support of Ford Motor Company.

Developed Sanitization Processes as per the NSF requirements.

Process Improvement Leader. (Lean/Six-Sigma Trained)

Customer-focused Supply Chain Manager and Problem Solver.

Developed, managed, and implemented Quality and EHS Systems from the High Seas to the South Pole and with manufacturing and distribution sites all over the world.

Expertise in TS 16949, ISO 9001 and ISO 14001 requirements and registrations.

Developed and re-engineered processes to make them more efficient and error free.

Hands-on Manager with a record of increasing sales and exceeding established goals both internally and externally with Customers and with Suppliers.

Management and mitigation of risks.

Mentor direct reports making them the best at what they do

Trained and implemented all elements of the ISO standards, as well as SPC techniques and HazMat safety.

Successful Implementation of DuPont and SafeStart Systems, behavior-based Safety Programs.

PROFESSIONAL EXPERIENCE

Hamilton-Sundstrand, Rockford, IL 2017-present

$20 Billion Global Aerospace Manufacturer

Sr. Quality Assurance Manager

Manages: 5 Quality Leads; 8 Quality Engineers; 1 Lead Auditor; 1 Quality Clinic Dr.; 1 QA Associate.

Restructured Quality Department to better support Aerospace Programs.

Streamlined the lines of communication between QA and the Aerospace Programs.

Developed, Implemented and Managed Quality programs. (13 total in QA Department)

CAPA/ Corrective Action

Restructured CAR/8-D reporting and analyses processes to reduce late responses.

Scrap Reduction Program

Cut Scrap % in half by removing erroneous data reporting throughout the process.

Internal Audit Process

Developed a plan to transition the current AS-9100C QMS to the AS-9100D standard.

Directed Continual Improvement efforts for the Division: Quality Tools, CAB, PDPR, Kaizen Events.

Mentoring staff and peers in the areas of Quality, Safety, and tolerance.

Weir Minerals-NA, Madison, WI 2016-2017

$3.5 Billion Global Pump, Valve, and Hose MFR.

Quality Assurance Manager

Manages: 2 Quality Supervisors, a Supplier Quality Engineer, a Senior Quality Engineer, 2 Sr. QA Techs

Developed, Implemented and Managed Quality programs. (13 total in QA Department)

CAPA/ Corrective Action

Restructured CAR/8-D reporting and analyses processes to reduce late responses.

Scrap Reduction Program

Cut Scrap % in half by removing erroneous data reporting throughout the process.

Internal Audit Process

Reduced Audit Corrective Action response times from 6 months to 30 days.

Organized Team to prepare and pass an audit by a major Oil Sands Customer to gain the business.

Developed a plan to transition the current ISO-9001: 2008 QMS to the ISO-9001:2015 standard.

Directed Continual Improvement efforts for the Division: Quality Tools, CAB, PDPR, Kaizen Events.

Mentoring staff and peers in the areas of Quality, Safety, and tolerance.

Hamlin Electronics/Littelfuse, Lake Mills, WI. 2013-2016

$800 Million High-Speed Reedswitch Assembly

Quality and Continuous Improvement Manager

Developed, Implemented and Managed Quality programs.

CAPA/ Corrective Action

Response Time reduced to: 4D: 5 days/8D: 15 days

Nonconforming Material

Turnaround Time < 48 hours

Scrap Reduction Program

Streamlined and clarified Reedswitch Visual Inspection Standards.

Pushed successful Process Improvement efforts despite transfer of business from Wisconsin to Asia.

Managed ISO-14001 (EH&S) Activities

Managed TS-16949 (Quality Management System) Activities

Performed Internal TS/ISO audits

Re-engineered Failure Analysis Process and Process for handling Returned Material.

LEAN Principles/Process Mapping

Supervised and mentored three Quality Engineers and two Test Engineers.

Acted as a focal point for communication both internally among other divisions and externally with Customers.

Restructured the Quality Department to best serve internal and external Customers.

Developed and Implemented Product/Equipment Validation Plans for the Operations transfer to Asia.

Consortium for Ocean Leadership, Washington DC. 2011-2013

Ocean Observatory Initiative (OOI)

OOI Project: $400 Million Project to construct four oceanic observatories.

OOI Quality and Safety Manager

Developed, implemented, and managed Quality and Safety Programs at multiple sites.

Developed, implemented, audited and managed an Internal and External Quality Auditing Program.

Managed Quality and Safety professionals at multiple sites.

Developed a Non-Conformance reporting System, covering multiple sites.

Completed permit applications and managed the Environmental Compliance Permitting Process.

Provided Quality and Safety Training for the OOI Project.

Implemented Lean Concepts in process design and re-design.

University of Wisconsin, Madison, WI. 2004 to 2011

IceCube Project: $270 Million Project to construct a neutrino-detecting telescope at the South Pole.

IceCube Quality and Safety Officer

Developed a Failure Review Board and Non-Conforming Material Process where all issues were closed, reducing the failure rate to approximately %. We anticipated a 10% failure rate.

Jump-started an organized problem-solving effort.

Introduced a Peer Safety Auditing Program at the South Pole.

Created the Incident Reporting Process at the South Pole.

Directed the Development of Emergency Evacuation procedures.

Hired and trained a new Quality/Safety Engineer as a back-up at the South Pole.

Oversaw the Safety Hazards Analysis Process for all systems at the South Pole each year.

Managed the process for the revision of the Job Specific procedures.

Organized all safety training each year.

NEWARK INONE (formerly Newark Electronics), Chicago, IL 1998 to 2003

$ 500 Million Distributor of Electronic Components/ 1500 employees

Quality Assurance Director

Managed 50 sites/ 20 subordinates. Management Representative for the Quality/ Business Management System. Developed process re-maps as required. Trainer in all facets of the ISO standards. Performed all corporate and plant DOT training.

Led cultural change in Warehouse by collectively designing and implementing a Quality Accountability Program.

Designed and implemented ISO-9001: 2000 conversion at Newark InOne in four months.

Directed and implemented the ISO-14001 EMS standard in seven months.

Enhanced Internal Quality Auditing and Corrective/ Preventative Action processes, cut CAR cycle time in-half (including Supplier CARs).

Created and implemented LEAN processes to address customer requests, instituted tracking system.

Developed Six Sigma process performance benchmarks. Instrumental in developing OTIF (Customer Service Level Metrics). OTIF performance increased 50% in two years. Enhanced and sustained several key Customer relationships including LHMC, Hamilton-Sundstrand, and Boeing.

Established On-Line (Intranet) availability of all Procedures/ Work Instructions.

Supplier Relations:

oWorked with Suppliers and Purchasing to resolve Quality problems through both site visits and Supplier meetings at Newark. Hands-on involvement with the Supplier Corrective Action process and the Nonconforming Material processes.

oPartnered with Suppliers and IT Group to provide integrated on-line MSDS availability.

oLed a cross-functional team, inclusive of our Supplier Base, in Automation for Manufacturer’s Certification storage, retention, and retrieval processes. Reduced retrieval time for MFR certifications by 90%.

oDeveloped and implemented a Supplier Checklist to rate Supplier’s overall performance to baseline Suppliers for Improvement.

Managed a HazMat stock transfer from one site to another.

Played a key role on Transitional Management Team in closing Chicago Warehouse. Managed Inventory Control/ Quality function that maintained 99% outgoing quality level through the final shipment as measured through SWARM.

TOTAL CONTROL PRODUCTS, Melrose Park, IL 1997 to 1998

$ 200 Million PC and Plant Process Controls Manufacturer, Major Automotive Supplier/ 100 employees

Quality Assurance Manager

Management Representative for ISO-9002 Quality System Registration.

Supplier Relations:

oPerformed on-site Supplier Assessments.

oWorked with Suppliers through site visits to solve problems. Frequent domestic travel.

oIntegrated Supplier Corrective Action data in TCP Corrective Action process for Process Improvement.

Developed a consistent Internal Quality Auditing Program.

Managed UL Audits.

Enhanced the Incoming, In-Process, and Final Inspection & Testing Programs. Initiated a process to track production line errors for process improvement and to reduce scrap and rework.

Developed LEAN Process Control Programs including: a Product Returns Policy, Lot Control Program, and a Bar-Coding Program.

TRIPP LITE, Chicago, IL 1995 to 1997

$225 Million Consumer Electronics Manufacturer/ 350 employees

Quality Assurance Manager

Management Representative/Project Manager for successful ISO-9002 Registration effort. Supervised and trained two Quality Engineers and eleven auditing technicians, both locally, in Mexico, and in Asia.

Designed and implemented ISO-9002 registration at Tripp Lite in seven months from concept.

Established Company-wide Corrective and Preventative Action system. Originated the Internal Audit function.

Supplier Relations:

oInstituted a 1st-Piece Approval System, on-site with Suppliers in order to reduce product deficiencies by 50%.

oFrequent International travel to train resident QA Technicians and to trouble-shoot production problems at Supplier’s facility.

oIntroduced statistical analysis to quantify Supplier problems for resolution. Cut number of problems in half.

oPerformed Supplier Assessments both domestically and internationally.

Commenced product reliability testing using a Life Cycle program in order to develop product warranty information.

Proposed, developed, and initiated Statistical Analysis to include customer complaints, customer returns, and plant product failures, resulting in fewer customer complaints and increased internal process efficiencies.

REMCOR PRODUCTS COMPANY, Glendale Heights, IL. 1992 to 1995

$40 Million refrigerated beverage dispenser manufacturer in partnership with Coca Cola and PepsiCo.

Quality Assurance Manager

Established and maintained quality programs in accordance with corporate directives and customer needs.

Instituted policies and procedures for ISO-9001 Registration. P3

Supplier Relations:

oEnsured Quality and on-time delivery by introducing a Supplier Rating System with Purchasing in order to track Supplier performance towards improvement.

oEstablished a system for Supplier Assessments to assist with process improvement. Performed these assessments and integrated these results back into the Corrective Action process for improvement.

oFrequent visits to Supplier sites for trouble-shooting and problem resolution.

Developed Internal Audit program that encompassed on-line product audits, internal quality metrics and workmanship standards.

Trained plant production staff in problem solving fundamentals and SPC techniques.

Developed Sanitization Processes in conjunction with the NSF.

EDUC

EDUCATION

Bachelor of Arts, University of Notre Dame, Notre Dame, IN.

PROFESSIONAL DEVELOPMENT AND AFFILIATIONS

Certified TS 16949 Auditor.

Judge for the American Society for Quality’s “International Team Excellence Award.”

Companies compete in major Process Improvement or Corrective Action efforts.

Certified Quality Auditor (CQA), American Society for Quality. Currently a Member.

Certified SafeStart Instructor.

Behavioral Based Frontline Supervisory Safety Training Certificate from DuPont.

Six Sigma Green Belt training, Hamilton, Sunstrand, and Lockheed Martin

Quality Control Academy-Various seminars in ISO-9001: 2000; Internal Quality Auditing;

Corrective & Preventive Action; Quality Planning.

Rockwell Automation ISO-14001 Seminar, Internal EMS Auditing (ISO-14001)

“Quality Improvement through Defect Prevention” Certificate: Phil Crosby Course.

(NAPM) National Association of Purchasing Managers, Presenter for own paper: “Purchasing

Inspection on a Shoestring.” View Engineering, Inc., Simi Valley, CA, Programmer’s

Certificate for CMM operation.

SME (Society of Manufacturing Engineers), Certificates for Geometric Dimension and Tolerance

and Inspection training.

Moderate fluency in the spoken, written, and in the reading of the German language.

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