Quality Engineer Injection Molding

KEVIN THOMAS DUDLEY

**** ******** ******, *******, ** 23513 757-***-**** (cell) ************@*****.***

SUMMARY: “Hands-on”. Certified Six Sigma Black Belt. Certified Quality Engineer (CQE) by the American Society for Quality (ASQ). Lean Sensei. Experience includes over twenty-three years as a Quality Engineer/ Supplier Quality Engineer / Quality Manager, ten in the Tier I automotive arena, over twenty in various instruction roles and eleven in the Military Defense sector.

TRAINING AND APPLICATIONS: Six Sigma Black Belt, Lean Sensei, Certified Quality Engineer, APQP and associated FMEA/PPAP/Control Plans/etc., ISO9001:2015/AS9100/ TS16949, SPC, Gage R&R.

PROFESSIONAL EXPERIENCE:

TABET MANUFACTURING, NORFOLK, VA 2015 to 2018

Quality and Continuous Improvement Manager

oLed Continuous Improvement and Quality for military and commercial technical products.

oSingle contact for Supplier and Customer Quality management.

oImplemented an improved Inspection system in the high Mix/low Volume environment through redesigning the internal First-Piece Yield approach. It now reflects measurable floor conditions and process correction instead of casting blame by departments. Reduced customer returns.

oLed the successful Tabet ISO 9001 2008 and the ISO 9001 2015 Surveillance Certifications.

oLed a team in a plant-wide 5S effort to improve the focus on core company Capabilities and increased company work Capacity. Designed one-piece-flow cell to reduce real time cycle time from weeks to hours for a standard customer weekly order, reducing cycle time from weeks to hours. Designed a Materials warehouse layout on the first floor to replace the one on the second floor which required all material to be transported on a rickety elevator, estimated to save over $200,000 in handling and labor costs plus undetermined lost material costs.

oImproved the efficiency of the CNC area through implementing Lean waste-removal efforts.

oWrote many work instructions for new company processes.

oDesigned and performed “Tabet 101” new employee training for all production employees.

NEWPORT NEWS SHIPBUILDING, NEWPORT NEWS, VA 2006 to 2015

SCM Supplier Development / Continuous Improvement and Quality Lead / Training

oDeveloped and implemented training, which is still in use, for the very large supply base. The training includes web-based self-directed learning, on-site training and larger training event approaches.

oLed a Supplier Development team using Lean, Six Sigma and Continuous Improvement applications.

oDeveloped and implemented procedures for all developed processes such as Supplier Selection, Continuous Improvement and Corrective Action and Audit management.

oCertified as a Six Sigma Black Belt. Project scope was to weigh the benefits of a Pipe material indoor warehouse, using benchmarked Rack and Lift system, projected to save over $950,000 a year with a 3 year return-on-investment (ROI). Many hours working in the yard with all levels of personnel.

oThe Lead for Continuous Improvement and Quality in the Supply Chain’s Compliance department.

oDeveloped the SCM Continuous Improvement (CI) process to meet division-focused priorities. Managed and oversaw CI projects for SCM. Compiled and managed to monthly CI status reports.

oDefined and developed Quality metrics to reflect the health of the division, in support of the Division managers in enacting precise division goals. Managed root cause analysis, corrective actions and responses to the Supervisor of Shipbuilding- Newport News pertaining to all CARs issued to SCM.

KEVIN THOMAS DUDLEY Page 2 of 2

JOHNSON CONTROLS, CHESAPEAKE, VA 2003 to 2005

Supplier Quality Engineer / Quality Supervisor / Quality Engineer

oSupplier Quality Engineer for mechanical and electrical commodities and assemblies.

oManaged the Production Part Approval Process (PPAP).

oManaged all Corrective Actions, Supplier Performance evaluation and improvement activities.

oCertified Six Sigma Green Belt. Project decreased 2,700 DPPM monthly average to less than 500 DPPM. Received Black Belt training.

oVoice-of-the-customer as the primary contact to the Ford Norfolk Assembly plant.

TEXTRON- JACOBSON, CHARLOTTE, NC 2000 to 2003

Quality Engineer / Lean & Black Belt member / Supplier QE

oParticipated on several Black Belt teams which reduced waste more than $250,000 per project.

oEstablished the machining and assembly cells relocated in a plant consolidation, with the application of Lean practices, Machine capability, ISO 9001, Kaizen and Kanban.

oDeveloped a Supplier approval plan for outsourcing parts to new vendors, including those to China.

DRAFTEX, SALISBURY, NC 1998 to 2000

Quality Engineer and Lean Implementer

oThe Quality member on a two-person team which launched 8 vehicle programs of a variety of sizes over 2 years. All process cells designed and implemented using Lean one-piece-flow principles.

oLaunched programs with 4 different Program Managers, all which accomplished <100DPPM within 2 months. Supervised 6 Quality Technicians.

oPrograms included Assembly, Extrusion, Plastic Injection Molding, Rubber Injection Molding processes. Produced and developed all documents for these cells such as Control Plans, Work Instructions, Boundary Samples and Boards, cell design layouts using Lean principles.

oSupervised and trained the Quality Technicians serving that product area.

COOPER-STANDARD, KITTANNING, PA 1993 to 1998

Quality Engineer / Plant Training Coordinator / ISO 9001: 1994

oPerformed all plant QE functions in the development of multiple programs. All programs maintained at < 500 DPPM. Quality levels for the144 Critical Characteristics were all 1.33 Ppk or above.

oPlant Training Coordinator for all personnel including all orientation and Statistical Process Control.

oDuring tenure, the plant doubled in floor space and product volume. Applied Lean techniques in all process cell development.

oISO9000 / QS9001 Management Representative and Document Coordinator for all quality system documents. Lead the QS9000 certification process in six months while not adversely affecting customer satisfaction. Led Internal Audits with scheduling, training of auditors and managing corrective actions.

ASSOCIATIONS AND CERTIFICATIONS:

oCertified Six Sigma Black Belt- 2008, Certified Six Sigma Green Belt- 2005

oCertified Quality Engineer (CQE) by the American Society for Quality- 2003

oCertified ISO9000 Lead Auditor- 1997.

EDUCATION:

oTwenty-four credits toward an M.S. in Management, Indiana University of Pennsylvania

oB. S. in Education- Indiana University of Pennsylvania

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