Quality Engineer Manager
Resume:
William F. Benca
Woodstock, GA
****.*****@*****.***
Background:
Degreed professional with extensive hands on experience with assembly tooling, manufacturing processes, roll forming, stamping, complex welded assemblies, seating systems, aluminum extrusions, Root Cause Analysis, SPC, TS16949, FMEAs, PPAPs, APQP, Control Plans, gage R&R, part tool & gage buy offs, Continuous Improvement, Corrective Actions, six sigma, lean manufacturing, standard work instructions, plant & supplier audits, supplier development; substantial knowledge of Chrysler, Ford, GM, Honda, Nissan, Toyota & BMW quality systems & requirements; Supplier Quality and Development have been integral functions in my career.
Experience:
Constellium May 13, 2013 to Present 2016 – present Quality Manager – White, GA; 2015 to 2016 Quality Manager - Van Buren, MI 21 direct reports; 2013 to 2015 Acting Quality Manager/Quality Engineer - Novi, MI
Successfully opened new plant in White, GA and launched new product for Customer
Established Quality System for new plant and trained new Quality Staff
Working on launch of 2 additional product lines for plant
Led Root Cause Investigations on internal and external issues at all 3 Plants
Reduced customer complaints from 4 per month to .7 per month for the last 17 months at Van Buren
Reduced scrap from average of over 2,400 parts/month to 1148/month in first 6 months on job
Initiated numerous improvements to processes to increase OEE - reducing non value added costs
Made two presentations to GM Upper Management at Lordstown for SPR’s to address customer issues
Instrumental in establishing written changeover & set up procedures for production lines
Reviewed & revised Control Plans & FMEA’s to correctly address potential issues & systemic problems
Completely revised quality system, added data collection to computers to facilitate SPC tracking, established tip points & SPC controls for processes
Created Training Coordinator Position and training boards to address inadequacies in training
Johnson Controls April 2010 -May, 2013 Corporate Offices Reason for leaving (Recruited by Constellium)
2012-2013 Senior Quality Engineer, Supplier Quality – 7 Direct Reports
Managed 17 programs, including Ford Transit with over 400 component parts
Worked with suppliers to supply high quality PPAP’s with all necessary documentation
Led efforts to improve quality at suppliers who were not performing to standards
Developed matrixes for supplier self-assessment and other tools to assist in evaluating status of readiness and necessity for follow up
Suppliers for my programs delivered PPAP’s on time 98.1% of the time
2010 to 2012 Senior Quality Engineer, Metals & Mechanisms
Prepared PPAPs for two facilities for Ford C346 program, approved supplier PPAP’s - led resolution of numerous issues during launch - prepared & tracked all supplier PPAP’s through SC/CC Matrix to comply with Ford mandate – worked with suppliers to improve processes and PPAP submissions.
Participated in numerous line safety walks at several plants - drove resolution & closure of open issues
Lead PPAP preparation for 051A at Battle Creek & Lakeview Plants for submission to Toyota
Participated on SWAT team at Battle Creek for 10 weeks; reduced poor quality costs & containment by 80% through process improvements on weld lines through root cause analysis and subsequent fixes to cells
Assisted with the analysis of data & processes to aid in the closure of Customer issues & safety problems & through working relationship with customer closed 9 PR’s that had been open for 6 months
2010 Advanced Quality Engineer, Toyota Business Unit, (Computech)
Reviewed internal and supplier tooling for stampings and assemblies, conducted weld audits, assisted suppliers with problem solving, improvement of metrics and assisted with PPAP submissions.
Was responsible for all supplied metal components for Ford 051A Program including PPAP approval
Was responsible for working with Suppliers to assist with PPAPs and improve metrics and OEE
Was named lead AQE for Toyota 170A Program - reviewed initial prints, designs – modified as necessary
Led closure of quality issue from suppliers by analyzing processes, suggested numerous improvements and resolved dimensional & tolerancing dispute allowing PPAP of component parts
Participated in numerous LRR’s, PRC’s and Customer reviews
Led weld audits at Suppliers and internal plants to comply with Toyota requirements
Global Automotive Systems 2006-2008 Corporate Quality Director (Corporate Offices) - 16 direct reports Reason for Leaving (During automotive downturn – downsized – 24 of 48 corporate employees remained)
Quality Manager of 19 facilities in United States, Canada and Mexico
In 2006 reduced Corporate Customer External PPM’s by 45% from previous year
In 2007 reduced Corporate Customer External PPM’s by an additional 17% from previous year
Established & Implemented Corporate Quality Standards and System; APQP Process & procedures; procedure for tool moves intra & inter company; metrics reporting tracking system for internal & external issues;
Worked with suppliers/company facilities to improve problem solving skills, including establishing the root cause of issues, the correction of same & the preparation of Corrective Action Reports
Oversaw the handling of major customer issues, negotiated & settled issues at Tier 1 & OEM customers including piece counts & charge backs as they pertained to dimensional, attribute, functional and/or appearance of parts with a high degree of success
Instrumental in the award of new work through DCX due to substantial improvement of quality metrics
Established procedure to share best practices and lessons learned throughout the corporation
Helped establish operator accountability for product throughout the corporation
Trim Trends 2004-2006 Reason for Leaving: (Purchased by Global Automotive) acting Corporate Quality Manager
Performed quality engineer & launch coordinator activities during launch at Nissan & Tower facilities
Reviewed & revised FMEA’s, Control Plans & Process Flows to insure accuracy of content & compliance with QS/TS & customer specific requirements
Oversaw preparation of PPAP documentation, as well as tool & part buy offs for 21 parts, engineering changes & introduction of new level parts into customer assembly process
Instrumental in stopping six (6) simultaneous sorts at Kokomo Transmission Plant for part issues, establishing root causes and correcting them, resulting in a change from having the worst supplier metrics at that facility to being offered additional work by plant management
Worked closely with suppliers & own manufacturing facilities to improve quality systems, manufacturing processes & responses to customer issues
Established & maintained excellent working relationships with customers and suppliers
Worked closely with customers to resolve issues & meet or exceed quality requirements
Tower Automotive/Active Metalforming Systems (Active purchased by Tower) 1996-2004 Quality Engineer/Quality Liaison
Leader of customer quality liaison group
Handled customer complaints at various Ford, Chrysler, GM, Honda & Toyota facilities, including negotiation of piece counts, charge backs, assisting internal plants in root cause analysis, hard tool modifications to prevent creation of defective parts, best practices & corrective action preparation
Actively participated in launches with Chrysler and Ford in Canada, Mexico, Brazil and the US
Launch support consisted of tool and gage buyoffs, root cause analysis for customer issues, 8D preparation, PPAP’s, review of FMEA’s, Control Plans, engineering changes, part try outs at customer facility
Assisted in & taught 8D training to various Tower Business Units personnel
Member of DaimlerChrysler Body Systems Audit Team for AN84 Launch
As part of customer launch team spent eleven (11) months at customer facility working with AME’s, dimensional control team & process engineers on customer & internal tooling
Member of Tower Automotive Core Quality Counsel & Tower Review Team
Taught Customer Expectations class to all new hires at Clinton Township Business Unit
Mentored and monitored suppliers to improve processes, quality systems and metrics
EDUCATION:
University of Notre Dame BS Chemistry
COU rses:
GM PFMEA Training Essentials of Leadership SPC Training
EHS First Leadership Workshop Economic Value Added Team Leadership
Geometric Dimensioning & Tolerancing Dimensional management Lean Manufacturing
Fundamentals of sheet metal stamping Welder Training/Inspection
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