Quality Engineer

Darrell Owen

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

Murfreesboro, TN 37127

270-***-**** (Email: *******.****.**@*****.***)

SUMMARY:

Recently worked with transition from ISO/ TS 16949 QMS to the new ISO/ IATF 16949 QMS

Spent 5 years as an external Lead Auditor for an AIAG Certified registrar for ISO 9001 and TS 16949 and performed over 450 audits for automotive and non-automotive quality system certifications.

Lead teams on improvement projects that increased productivity, scrap reduction, new cell layouts for reduced work-in-process travel, improved gauging along with equipment and tooling cost savings.

Supplier Quality Engineer that improved suppliers’ quality, gauging, delivery and their quality management systems.

Twenty-plus years’ experience as a Manufacturing/Quality Engineer providing production, training & quality support.

EDUCATION:

Purdue University

oBachelor of Science in Mechanical Engineering

oISO 9001: 2008 and ISO 9001:2015

oTS 16949:2009 and IATF 16949:2016

PROFESSIONAL EXPERIENCE:

Kasia North America (2016 – 2018)

ISO 9001:2008 / TS 16949:2009 Transition to ISO 9001:2015 / IATF 16949:2016

Corporate Quality Management System Auditor

Worked with team to complete transition of ISO/TS 16949:2009 Quality Management System to new IATF 16949:2016 Quality Management System for North American Corporate Headquarters in Murfreesboro, TN.

Completed internal audits at the (6) manufacturing sites and (3) design sites preparing for 2-semi-annual TS 16949 based external audits that helped them to pass to maintain their certification.

Worked with team to complete transition from ISO ISO/ TS 16949 QMS to the new ISO/ IATF 16949 QMS at the various (6) manufacturing and (3) design sites this year and prepare for the next external audits.

Douglas Autotech (Aerotek) (2016)

Supplier Quality Engineer (Contract)

Worked to complete all external supplier part quality issues from internal and external quality issues.

Internal - The containment activities to have the affected parts tagged and removed from the assembly line and inventory to be sorted to keep the line running.

External - Contacting suppliers about quality issues and working with them to perform containment along with the root cause and corrective actions along with coordinating to receive expedited clean-point certified parts to run.

Successful in resolving quality problems with 55 active suppliers for non-conforming parts.

Martinrea, Metalics Division (2015)

Quality Systems Engineer (Contract)

Re-developed the current TS-16949 Quality Management System to help us get the certification back; was removed.

Completed the Internal audits with 78 findings and completed the corrective actions in preparation for Stage 1 Audit.

Assisted in preparation and successful GM / BIQS Audit.

Completed the training of production operators to understand the importance of TS-16949 and their role in quality.

Worked with production operators and engineers to do the root cause analysis for internal audit corrective actions.

Rexnord Bearings (2014 – 2015)

Project Manager of Quality Improvement / ISO-9001:2008 Auditor (Contract)

Completed 31 ideas for reducing scrap, better part quality and process documentation improving on-time-delivery

Revised the ISO-9001:2008 Quality Management System to make documentation match what was being done

Performed the ISO-9001:2008 Internal Audit for all revised identified processes and documentation / records

Audited all 251 production-related operators to verify ISO-9000 knowledge, job training & readiness for being audited

Performed weekly department audits for Management Team generated Quality and Manufacturing improvements

Managed the weekly department audit scores for various processes and improvement trends in weekly reports.

Completed Process Flows, PFMEA's for The Turning and Grinding Departments prior to the end of contract

Rolls-Royce (2012 – 2014)

Supplier Quality Engineer (Contract)

Managed the Quality of products for 35 suppliers (foreign & domestic) in the Installations and Controls Group.

The products were for External Product Commodities for various Jet Engines for the US, UK, France & Germany.

Coordinated with my supplier base imperfections to complete corrective actions preventing recurrence of issues.

Completed customer complaints / supplier issues starting with 168 complaints (while gaining 15-18 per week) down to 4 open complaints when my contract of 2 years was completed.

Communicated regularly with various customers to review the progress of the corrections and the timing / completion.

Faurecia Exhaust Systems, Inc. (2011 – 2012)

Quality Engineer (Contract)

Coordinated completion of Ford Q1 Documentation required to regain the Q1 talking with Ford after we lost it for quality and documentation issues.

Redeveloped to Ford Standards the Process Flow, PFMEA, Control Plan,1st Pc Verification Sheets.

Redeveloped Process Work Instructions for the welding cells working with the operators reducing tooling issues.

Updated the process improvement changes from 2011 Internal Audit findings, corrective and preventive actions.

Completed 2012 Internal Audit as Lead Auditor and led the root cause corrective action / implementation process

Completed over 100 customer complaint corrective actions that had not been addressed for some length of time.

Kolortech, Inc. (2009 – 2011)

Lighting Specialist Sales Engineer

Sold Industrial / Commercial Lighting focused on problem solving, saving energy and continual improvements.

Developed customer base by getting to know them as a trusted friend that was trying to solve their problems.

Allison Transmission, Inc. (2008 – 2009)

Advanced Supplier Quality Engineer (Contract)

Completed product design changes for supplier implementation with Product Engineering and Purchasing Personnel

Completed improvements to supplier processes, gauging choices/techniques and product quality prior to shipment.

Assessed supplier TS16949 quality management systems on how they supported their manufacturing processes.

Prime Products, Inc. (Precision & CNC Machining) (2007 – 2008)

Manufacturing and Quality Consultant (Contract)

Completed 6-Sigma-Based project for motor frame machining line improving productivity by 21%, scrap reduction by 32%, tooling cost by 29% and machine tool life by 31%. Updated all work instructions and trained operators to them.

Completed project with CNC Process Engineers to reduce cycle times by 14% with new style tools and tool holders, improved coolant flow, program changes and improved cell layout. New layout reduced distance of travel & motion.

Implemented 5-S, layered 5-S daily employee audits, 5-S weekly management audits and department information boards for improved communication and improved organization throughout the Plant to gain new automotive business

Resolved all supplier issues with improvements and customer complaints resolved by corrective & preventive actions.

Implemented new employee evaluation, training methodology, trained trainers, and new work instruction programs.

Developed TS-16949 Compliant Quality Management System for ISO-9001:2008 system and received certification.

Intertek Systems Certification, Inc. (formerly Entela, Inc.) (2002 – 2007)

Certified North American Lead Auditor

AIAG / IATF & ANAB certified Lead Auditor for ISO-9000:2000, QS-9000:1998 and TS-16949:2002

Performed over 450 Quality Management System certification audits in Mexico, Canada and USA facilities

VALEO INC., Rochester, NY and Juarez, MX (2000 – 2002)

Senior Mfg. Engineer / Maintenance Supervisor

Completed the relocation of the PM/DC motor product line from the Rochester, NY facility to the Juarez, Mexico facility generating $5 million plus annual savings. Led Mexican machine shops for complete equipment refurbishment.

Led completion of PPAP’s for 8 GM Assembly Plants and gained customer approval for power window lift motors.

Managed the maintenance department personnel and several continuous improvement project implementations.

Redesigned tooling to downsize from three to two assembly lines. (Savings of $350K/year)

Procured design & build and Implemented automated material handling conveyors for $240K/year labor savings.

Revamped preventive maintenance activities reducing downtime by 21% and overtime by 11%.

Worked with suppliers to reduce their costs, scrap, wasted motion in process and inventory using lean tools.

API MOTION, INC., Racine, WI (1998 – 2000)

Manufacturing / Quality Engineering Manager

Managed quality and mfg. for the relocation, training and implementation of electronic motion control products from domestic and European countries to the West Indies island of St. Kitts for annual savings of over $3 million per year.

Completed design, purchase and implementation of new servo motor and stepper motor assembly equipment using single-piece flow and other lean principles for these new products as well as implementing gage calibration program.

Created all work instructions for assembly and inspection (visual & gauge) for each operation and trained all operators using the work instructions. Performed process capability studies and Gauge R&R studies using operators.

Reduced costs with die casting, machining and component suppliers by improving their quality, and delivery to save $28,027 annually and gained new customers through price reductions along with 14% less customer returns.

LUCAS VARITY and STEGMANN, INC. DAYTON, OH (1995 – 1998)

Senior Mfg. / Quality Engineer & Buyer

(Optical Encoder Product sold to Stegmann, Inc. after the first 2 years)

Reduced material costs by $247,873 for $4 million of projected sales working directly with suppliers creating win/win relationships. This was done through setting up Kan Bans, consignment purchasing and blanket purchase orders that allowed suppliers to deliver their products at their convenience to us.

Performed supplier development through on-site visits to suppliers for corrective actions & continuous Improvement.

Spearheaded p.c. board, and sub-assembly of components outsourcing to suppliers resulting in $51K annual savings.

Reduced assembly time by 25% and quality rejects by 11% with help from team of operators & new assembly fixtures.

Implemented UV-curing adhesives reducing product lead time by 1 day, assembly time by 25% and scrap by 43%.

A.O. SMITH PRODUCTS, Juarez, MX (1994 – 1995)

Senior Manufacturing Engineer (Contract)

Helped Plant Manager remodel and refurbish acquired plant for production readiness and hired maintenance staff.

Implemented new pull system for HVAC motor assembly using lean principles saving $223K annually by the relocation and redesign of the equipment and processes from the Ohio facility. Implemented quality and gauging too.

Implemented new paced conveyors with equally-spaced product increasing productivity (savings included above).

Created operator instructions and trained operators for receiving, assembly, inspection and packaging.

Managed the Quality Department during absence of manager and improved the inspection and gauging activities.

HUFFY BICYCLES, Celina, OH (1992 – 1994)

Senior Manufacturing / Quality Engineer

Worked with Purchasing to improve supplier’s processes to receive higher quality components per customer request.

Increased bicycle production by 12.7%, quality by 8.5% and improved ergonomics to eliminate Carpal-Tunnel injuries.

Created new work instructions for better assembly and inspection methods working with a team of operators.

Reduced model changeover time 14% working with a team of operators for continuous improvements.

Increased wheel production 18.4% and quality 8.7% working with a team of operators.

Implemented new preventive maintenance program working with maintenance people gaining 22% more uptime.

DELCO REMY DIVISION GM, Anderson, IN (1983 – 1992)

Manufacturing / Product Design Engineer / Supervisor

Completed project to design, build and implementation for project to build 6-K starter motors/day in Meridian, Miss.

Completed project to design, build and implement project to build 10-K alternators/day in Juarez, Mexico.

Developed and implemented new internal corrosion resistant coatings and new supplier for starter motor parts.

The coatings mentioned above created a savings of 18% (for 6 million starter motors/year).

Sent to coating supplier to lead design, build and implementation of powder & liquid coating systems for new coatings.

Key Product Design Team member for the design, development and validation of a new PMGR starter motor.

Developed new 2-piece gear reduction starter shaft and process to assemble saving material & machining cost.

Key team member to develop and implement plasma arc, resistance and TIG welding processes.

Key team member to develop and implement induction-hardening process for the new starter motor shafts.

Designed, developed and implemented new alignment tooling for rotor assembly increasing output by 11%.

Managed Maintenance Department in motors plant with 3 shifts lowering overtime by 18% and implemented new

preventive maintenance activities that reduced equipment downtime by 13% and maintenance work orders by 16%.

Supervised tool room and machine build activities that improved lead time for projects by 8%. Implemented a team of toolmakers to review all machine prints for accuracy, proper materials and mating piece tolerances prior to authorizing work on projects reducing remakes and scrap by 21% and unnecessary labor and machine time costs approx. 17%.

TRAINING:

ISO/QS-9000:1998 Lead Auditor Certification from AIAG

ISO-9000:2000 Lead Auditor Certification from RAB/ANAB

ISO/TS-16949:2002 Lead Auditor Certification from IAOB

Supervisor and Labor Relations Training.

Automotive Electrical Systems

Statistical Process Control

Production Equipment Validation

Machine and Tool Design and Drafting

Shanin Failure Mode Analysis

Taguchi Experimentation

Design of Experiments

Kaizen

Six Sigma Yellow Belt

Design for Assembly

Design for Manufacturability

Synchronous Manufacturing

Single-Piece Flow Manufacturing

SMED for Quick Product / Production Changeovers

Holshin Problem Solving and Solution

MSA (Measurement System Analysis)

DFMEA (Design Failure Mode & Effects Analysis)

PFMEA (Production Failure Mode & Effects Analysis)

APQP (Advanced Product & Quality Planning)

PPAP (Production Part Approval Process)

QSA (Quality System Analysis)

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