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Quality Engineer

United States
August 09, 2018

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Thomas J. Lyon

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

Westville, IL **883



I am a hands on person that leads by example. My goal is to provide excellent customer service and assist the company to become more competitive and profitable utilizing my acquired knowledge, experience and abilities. Willing to do whatever it takes to get the job done correctly, on time and within budget.


Six Sigma Black Belt trained through Caterpillar.

Knowledgeable in QS9000 and ISO9000 system and internal process and quality audits.

Knowledgeable and skilled in FMEA, PPAP, SPC, APQP, control plans and continuous improvement.

Trained as a quality inspector, use of measuring tools, gage R&R, blue print reading.

Highly customer focused.


9/17 – 3/18 Quality Engineer/ Manager, T&D Metal, Watseka, IL.

Responsible for the overall quality of all parts made at the Watseka facility.

Respond to quality issues reported by Caterpillar and other customers.

Conduct internal investigations, root cause and 8D corrective actions on all nonconforming products.

Direct two non-degreed technicians.

10/16 – 9/17 Quality Engineer, Charles Industries, Rantoul, IL.

Responsible for the overall quality of all enclosures produced at the Rantoul and Marshall facilities.

Update and publish daily production and quality results.

Supervise quality staff on two shift operation.

Conduct internal investigations, root cause and 8D corrective actions on all nonconforming products as reported on the Charles corporate portal.

3/16 – 8/16 Quality Engineer, Doncasters Inc., Paris IL.

Responsible for the overall quality of all product produced for Rolls Royce Corp.

Conduct daily customer meetings to discuss quality, production and delivery issues.

Issue deviation requests and follow product through the rework process on all nonconforming product.

Conduct internal investigations, root cause and 8D corrective actions on all nonconforming Rolls Royce products.

Quality representative on new product review team.

6/08 – 2/16 Supplier Development Engineer, Caterpillar Inc., Decatur IL.

Responsible for quality of all products related to the assembly of the mining trucks. Includes (not limited to) tubes, wire harnesses, metal and aluminum castings, motors, pumps, metal assemblies.

Directed to reduce rejections by 25% each year for 3-4 high defect suppliers.

Issue corrective actions to suppliers that produce nonconforming materials then work closely with suppliers to update their processes to insure corrective action is robust and functional.

Team leader of 15-20 projects (each year) from both the shop floor or field reports of quality related issues for the large mining truck products.

Responsible for site review of PPAPs, control plan and pre-delivery quality records. Worked with several suppliers on new product launch (APQP).

Attend and actively participate in the daily BIQ (Built in Quality) process on 11 different models of mining trucks.

Six Sigma Black Belt project, eliminated $50,000-100,000 in unnecessary yearly rework on the C32 engine program.

10/05 - 6/08 Validation Engineer, Geometric Engineering, Peoria IL.

Personally facilitated resolution on over 600 assembly and design issues during new engine design rollouts at Caterpillar’s Mossville facility.

Maintained corrective action database within my assigned work group.

Participated as active member in DFMEA and APQP meetings.

Provided engineering support to the manufacturing, quality and assembly departments.

4/03 - 2/05 Quality Engineer, Arkay Industries, Paris IL.

Directly responsible in reducing defective material PPM from 16,000 to 200 to largest customer (Subaru). Training of both Arkay and Subaru people on rejection criteria and resolution process.

Trained all Arkay operators on every updated work instruction.

Managed and maintained all calibration records and equipment for two plants.

Knowledgeable in FMEA, PPAP, SPC, APQP, control plans and continuous improvement.

Investigate and handle supplier situations, customer complaints and concerns both at Arkay and at the customer.

Past positions:

8/02 - 12/02 QUALITY MANAGER, Novapak Inc., Paris IL.

10/00 - 8/02 QUALITY ENGINEER, Vermilion Rubber Technology, Danville, IL

6/98 - 8/00 PRODUCTION and QUALITY SUPERVISOR, Krupp Gerlach Co. Danville, IL

5/97 - 1/98 QUALITY ASSURANCE SUPERVISOR, Cerion Technologies, Champaign, IL


*Manager for 24/7 operation of quality department - 11 non-union employees (Novapak).

*Supervisor for 1st and 2nd shift quality departments - 4 union employees (Vermilion Rubber).

*Supervisor for 2nd shift production and quality departments - up to 25 union employees (Krupp).

*Supervisor for 3 shifts - 80 final inspectors, 3 inspection trainers and 3 AQL inspectors (Cerion).


Bachelor of Art in Chemistry, Lakeland College, Sheboygan, WI

QS-9000 Internal Auditor course, Jaeger-Holland

DMAIC 6 Sigma Black Belt Training, 9/08-12/08

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