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Quality Manager

Location:
Lapeer, Michigan, United States
Posted:
November 28, 2018

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Resume:

CHARLES JOHN STICKNEY

MS ASQ CQE CQA ISO TS AS

*** ***** ** ****** ** 48446

E: ac7tkz@r.postjobfree.com

C: 586-***-**** H: 810-***-****

SUMMARY OF SKILLS AND QUALIFICATIONS

•Quality Manager – Senior Quality Engineer Specialist - Supplier Quality Development Engineer and Auditor highly organized and energized self-starting professional who is a success oriented team player with strong analytical skills. Possess excellent written, oral, and interpersonal communication skills. Ability to thrive in a fast paced challenging environment with integrity and professionalism. Focus on strong client service with excellent follow up skills and an aptitude to prioritize and multi-task.

•Responsible for Advanced and Current Product Development Engineering and Management.

•Expertise in Product Supply Chain Engineering with developing, implementing and auditing a range of products, materials and manufacturing processes required for product development working with both internal and external processes for domestic and international suppliers.

•Proficient at APQP and product development management leading PPAP for advanced and current product development through PPAP with manufacturing equipment and processes required in production.

•Conduct on-site audits and qualify suppliers based on observations and actual production product dimensional data and conduct capability studies on the development of components and products.

•Develop/implement Six Sigma processes and lead improvement activities to create and maintain lean manufacturing strategies while tracking critical program timing to meet the customer requirements.

•Audit Six Sigma's methods and the use of measurement and improvement tools, and in communications and relationship skills.

•Lead Six Sigma DMAICT teams and team leaders responsible for implementing process elements.

•D - Define opportunity, M - Measure performance, A - Analyze opportunity

•I - Improve performance, C - Control performance, T - Transfer best practice

•ENOVIA PLM product lifecycle management utilized to support the product development processes from concept CATIA design to manufacturing.

•Quality Function Deployment (QFD) is a method of product development where the product or process is directed from the Voice of the Customer (VOC) through development of requirements, specifications design feature development, process selection and process control.

•Design Verification Plan and Report (DVP&R) verification and validation process of tests and evaluation techniques to provide confidence that the design is reliable meeting customer expectations and specifications.

•Review audit and qualify product development stages and quality systems including; inspection processes and documentation; vendor outsourcing to lower tier vendors

•Conduct on-site vendor certification for current and new suppliers for product development. Liaison with Design engineers to achieve Design for Manufacturing and assembly.

•Coordinate vendor transitions and start-up operations with development into fully functional suppliers.

•International experience working with Chinese, British, German, Italian and Canadian companies.

•Lead DFMEA/PFMEA Failure Modes Effects and Analysis (FMEA) and Failure Modes, Effects and Critical Analysis (FMECA) to achieve high quality designs, processes, and services that meet or exceed industry standards.

PROFESSIONAL EMPLOYMENT EXPERIENCE

DRAEXLMAIER AUTOMOTIVE of AMERICA DAA LLC. Duncan SC. / Troy MI. 07/2012– Present

Quality Development Expert – Customer Quality Lead Interior Systems Contract

•Program and Project Management responsible for product development and planning of tasks that aligns with the goals of the Development Quality Department in the context of project launch activities. Tasks span multiple classifications to allow for flexible resource management within the Development Organization. Leverage knowledge of quality principles to assist in the mentoring of Development Quality Personnel.

•Specific focus areas include the development of quality concepts, inspection plans architecture, quality system inspection plans, and appearance manuals. Support quality development activities with measurement plan evaluation and interpretation of measurement reports and inspection methodologies. Support Quality Deployment tasks including resource definition and budgeting. Interface with Customers and Managerial levels as required to complete these project activities.

BAE SYSTEMS/FORCE PROTECTION Chambersburg PA/Charleston SC. 01/2007 – 07/2012 Customer Quality and Product Development including Manufacturing Systems Capability Process Engineer and contractor consulting for TAC WORLD WIDE

•Program Management responsible for product development and planning of capital equipment required for producing MRAP vehicles for the Military. Leading both People and Projects, developing product and processes that drive improvements initiatives for Six Sigma lean manufacturing. Strategies and the acquisition of new equipment/processes, workplace layouts, labor and material flow with business process modeling to meet company strategic goals.

•Manager of both Internal and External Product Development leading the DFMEA Team in a suitable design and system components to ensure the safety and reliability estimation and analysis of the system. Utilized QFD within the Product Development Team, for ensuring that requirements are captured, disseminated, monitored & controlled to ensure compliance with customer, legislative, drawings, specifications & standards. Working knowledge of International Standard IEC 61508 for functional safety of electrical or electronic safety-related systems. Validate safety life cycle for functional of safety-related systems to reduce risks.

•Lead internal (customer) and external (supplier) APQP and PPAP for meeting Governments Contractual build requirements meeting the International Standard TS16949 requirements in the development of a quality management system (QMS). The QMS I developed provided for continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply chain.

•Heavy Metal Fabrication, body sheet metal, stampings, castings and forgings for power train and chassis. Lead multi-disciplinary product engineering team members. Develop, investigate and solve manufacturing process to improve cost, quality, delivery and safety of manufacturing processes by value stream mapping and improving process flow.

•Aluminum Fabrication, body sheet metal, stampings, castings and forgings for power train and chassis. Lead multi-disciplinary product engineering team members. Develop, investigate and solve manufacturing process to improve cost, quality, delivery and safety of manufacturing processes by value stream mapping and improving process flow.

•Responsible for both Metal and Aluminum Fabrication Leading a wide range of precise fabrication capabilities including precision cutting and mitering to size, milling, drilling, punching, engineering and C.N.C. capabilities.

•The primary driver of the Six Sigma team and team leaders that continuously and significantly improves key manufacturing processes to drive greater organizational efficiency. Leading multi-disciplinary teams in Six Sigma business process modeling and improvement initiatives.

•Team leadership for championing lean process methodologies to create a culture and drive continuous process improvements, and successfully plans, develops, administers, and executes specific process improvement projects; including training those who will use the new business process models.

ACCOMPLISHMENTS:

•Created a Six Sigma lean process for vehicle development which took the company from producing 2 mine resistance ambush protected vehicles (MRAP) per month to 54 vehicles last month netting $54 Million in sales which completed the two year Government contract.

•Develop, investigate and solve manufacturing process to improve cost, quality, delivery and safety of manufacturing processes by value stream mapping and improving process flow by (75%) seventy five percent.

•Improved first time through process capability from a 50% failure rate to 1- 2% failure rate found at final inspection.

RAPID GLOBAL BUSINESS SOLUTIONS INC. CONTRACT COMPANY TROY, MI 01/2004-01/2007

Senior Customer Quality and Supply Chain Engineer on assignment to:

JOHNSON CONTROLS SEATING TOYOTA BUSINESS UNIT, Plymouth, Michigan One Year Contract

Senior Quality Engineer Supply Chain and Customer Quality 01/2006-01/2007

•Managed Toyota Business Unit Customer Quality and Product Development Teams to ensure the quality of supplier pre-production for plastic, foam and stamped metal components through use of APQP tools. Responsible for equipment/processes to accommodate and build part design validation and gauging serving as the key manufacturing representative between supplier and engineering on Toyota programs and in meeting part requirements for producing both pre-production and production seat build activities. Led the JCI Toyota Product Development Teams and external Supplier Development Teams with new product development. Responsible for ISO and TS conformance requirements.

•Provided technical guidance for quality systems, customer support, supplier assessment, and problem solving facilitation. While at JCI assisted Quality and Production departments in daily activities. Utilizing practical applications of quality tools and worked operational management roles as a mentor and coach with plant production management and employees. Serve as a direct quality and production responsible manager of a corporate technical team as well as a successful consultant responsible for serving both the advanced and industrial manufacturing sectors in the product development processes. Conducting in house on-site Product development and capacity analysis review of run at rate line speed demonstrations in meeting daily and annual production volumes. Conducting risk evaluations and completing internal audits.

ACCOMPLISHMENTS:

•Full Customer – Toyota PPAP Level 3 PSW approval for my APQP work with the entire Toyota Product Development Teams both internal customer and external supplier development.

•JCI was awarded the Toyota Business Account with an estimated volume of three hundred thousand vehicles.

•Received a letter of recommendation for my contributions work performance and team ethics from the Director of JCI.

FAURECIA AUTOMOTIVE SEATING, Auburn Hills, Michigan One Year Contract Employment

Senior Customer Quality Engineer and Supply Chain Management 01/2005-01/2006

Manager of Customer Quality and Supply Chain Development Analyzing Information, Reporting Results, Technical Understanding, Promoting Process Improvement, Developing Standards, Managing Processes, Manufacturing Methods and Procedures, Supports Innovation, CAD, Quality Engineering and Operations. Responsible for serving as the key quality management representative between the suppliers on part requirements to meet daily production build activities. Lead the Product Development Teams and external Supplier Development Teams with new product development. Addressing supplier capabilities product validation and addressing non-conformance to design requirements

•Lead supported and provided technical guidance for quality systems, customer support, supplier assessment, and problem solving facilitation. Assist the Purchasing, Quality, and Production Control departments in day to day activities. Provided practical applications of quality tools and worked operational management roles as a mentor and coach with plant production management and employees. Serve as a direct quality and production responsible manager of a corporate technical team as well as a successful consultant responsible for leading both the automotive and industrial manufacturing sectors in the product development processes and production manufacturing. Managerial and system related responsibilities have included both quality and engineering management in product launch and production activities including supplier development.

•Durability & Reliability testing carried out in both design and non-design responsible production and supply chain management. Involvement includes the studying of the Scrap and Cost Reduction Programs including leading and the facilitation of new product launch conducting on-site capacity analysis review of run at rate line speed demonstrations in meeting daily and annual production volumes.

•Conducting Supplier risk evaluation for new source selection and completing both internal and external audits to ensure the quality of supplier production for plastic, foam and stamped metal components.

ACCOMPLISHMENTS:

•Full Customer – GM PPAP Level 3 PSW approval from my APQP work on the Pontiac G-6 with the entire GM Product Development Teams internal customer and external supplier development.

•Faurecia was awarded the GM Business Account for the Pontiac G-6 with an estimated volume of two hundred and eighty thousand vehicles.

•Received a letter of recommendation for my contributions work performance and team ethics from the Quality Manager.

AMERICAN SPECIALTY CARS, Oak Park, MI, Contract Employment

Senior Quality Reliability Engineer Supply Chain Development and Customer Quality 01/2004-01/2005

Manager of GM Customer product development teams to ensure the quality of production components PPAP through use of APQP tools. Responsibilities: Product development for electronic components, printed circuit board assemblies. Control panels and wiring harnesses for GM Chevy truck programs. Sheet metal BIW, stampings, castings and forgings on power train and chassis. Serving as the key quality management representative between engineering and suppliers on part requirements for production build activities. This entails assessing supplier capabilities product validation and addressing non-conformances to design requirements. Utilized Reliability and Product Life-cycle Management PLM software as an integrated tool for product life-cycle analysis. Provide guidance to other Advanced Supplier Quality Engineers on PLM usage. Develop and implement best business practices for product development and the approval processes.

ASC designed, developed and manufactured the GM Chevy SSR Signature Series Trucks:

•Product development Quality and Reliability planning (Interior-Exterior). Support vehicle platform reliability and warranty analysis. Worked on RFQ in case of Program taking into consideration surrogate warranty. Lead warranty agreement meeting by forecasting warranty from trend analysis. Involvement with design engineer for future product Reliability Predictions. Characterizing statistical life fatigue parameters with reliability simulation software.

•Lead the Customer GM team to ensure quality and reliability of production components through use of APQP tools. Responsibilities: Sheet metal BIW, stampings, castings and forgings, power train and chassis. Reliability predictions were used to evaluate and improve product and system reliability. ASC had to meet or exceed the Reliability and Warrant requirements per GM terms and conditions. I was responsible for the Quality planning of both assembly and component level. Program Management to include tracking of events and team management toward quality goals at the supplier level and customer level. Drive continuous improvements activities while developing work plans for the Quality Department. Coordinate APQP meetings and activities for the Quality Team. Conduct Supplier On-site Process Approval to assure Quality and On-Time delivery of components and sub-assemblies.

•Develop processes and plan capital equipment to support Prototype, Pre-Production, and Production, requirements for PPAP parts to obtain customer approval of the Part Submission Warrants. Develop solutions to quality related issues while watching costs and minimizing risks. Coordinate with other Departments and audit Departments and provide quality improvement leadership to ensure effective and efficient. Define development implement and train new processes for team building, quality, safety, housekeeping, costs and timing for implementation. Track organizational goals and ensure team members are in compliance with company policies and procedures. Work with Engineering to determine significant key characteristics and track performance both internal and external.

ACCOMPLISHMENTS:

•Full Customer – GM PPAP Level 3 PSW approval from my APQP work on the GM Chevy SSR Signature Series Trucks with the entire GM Product Development Teams internal customer and external supplier development.

•ASC was awarded the GM Business Account for Design Development and Production of the GM Chevy SSR Signature Series Trucks with an estimated volume of fifty thousand vehicles at $50K each.

•GM Lead SQE and Program Manger requested ASC to provide my services and presents on all the GM Chevy SSR Signature Series Truck Business.

•Received a letter of recommendation from my contributions work performance and team ethics from the Quality Supervisor.

DAIMLERCHRYSLER Auburn Hills, Michigan Contract Employee 01/1997-12/2003

Corporate Quality Manager

Lead and Champion for QS ISO and TS registration activities for DCX Corporate Quality Vehicle Platform Support including Supply Chain. Responsible for the development of the required documentation with procedures, work instructions, training, implementation and auditing of all three Standards QS, ISO and TS. Developed and completed internal auditor training courses (QS9000, ISO 9001, and TS16949). MRB (Material review board) run (scrap, rework, return to supplier transactions). Development Internal audits and documentation as per requirement of QS, ISO, TS. Conduct Surveillance audits through both internal and external DCX Corporate Sites and Supply Chain validating Quality System compliance. Auditor and team leader in developing, implementation, training and auditing to the required standards.

Senior Manufacturing & Reliability Engineering Specialist

Manager of a Product Development Team leading workshops regarding internal/external awareness in Product Development Progress and Process Sign-Off (PSO) analysis and usage of Powerway.com with PLM software as an integrated suite of Product Life-cycle Management. ENOVIA PLM utilized to support the product development processes from concept CATIA design to manufacturing.

Co-ordinate, Facilitate, and Lead Product & Process Teams for Advanced Product Quality and Reliability Planning. Responsibilities include leading Product Development Teams on Concurrent Engineering, New Product Development and systems reliability predictions Product Change Management utilizing CATIA 3D CAD for product design changes and Powerway.com for tracking Supplier development. Provide DCX Production Plants the support and technical guidance for improving quality systems, customer support, supplier assessment, and problem solving facilitation.

Procurement & Supply Quality Process Improvement Specialist, Supplier Development Advanced Projects, Responsibilities, Co-ordination of Advanced Product and Process Quality Planning (APQP) Activities.

• Process Consultant and Facilitator leading the implementation of 6 sigma culture in union environment for the following Platforms minivan, truck, large and small car. Product development for electronic components, printed circuit board assemblies. Control panels and wiring harnesses for Chrysler truck programs. Six Sigma DMAIC approach for effective reduction in overall costs and warranty long term. Managed internal Product Development Teams and Supplier Development Teams with the APQP PSO PPAP. Activities include the definition, implementation, and improvement of internal and external supplier quality-related practices and procedures in supporting the organization with services and solutions using Quality Tools in meeting company goals and objectives.

ACCOMPLISHMENTS:

•Implementation of 6 sigma reduction in scrap and rework by (30%) thirty percent.

•Kepner Tregoe's approach, implementation of quality system in union environment.

•Design of Experiment (DOE) and capability study for AC/HVAC proved to be successful the Sebring AC/HVAC Dealer warranty cost dropped dramatically thirty percent (30%) over the next ninety (90) days.

•Sebring production of the Heater Core for the AC/HVAC System (60%) fall-out of Heater Cores during production. SPC monitoring and controlling their in-house manufacturing processes the fall-out or failure rate was reduced by sixty percent (60%).

•Dodge Durango platform manufacturing production plant seventy five percent (75%) fall-out for drips and sages on the rocker panels paint line. Redesigned the Rocker Panel to correct these failures. Results went from a seventy five percent (75%) failure fall-out rate to zero percent (0%) failure fall-out rate.

•Design the Chrysler 300M responsible for facilitating the DFMEA for this new concept vehicle for the Daimler European Market. Discover failure modes European garages were smaller than the average USA garages. I approached the PDT with my finding and the decision was to reduce the vehicle length. The Design teams redesigned the 300M and shorten the vehicle by reducing the trunk size and deck lid. The redesigned trunk and deck lid style appealed to both the European and the USA Markets. The style won JD Power Awards for Car of the year.

•Receiving certification to QS9000:1994, ISO 9001:2001 and ISO/TS16949:2002 Standard from United Laboratories.

•Promoted three times in five years and part of team for Malcolm Baldridge Award.

PLASTIC SPECIALTIES INCORPORATED, Troy, Michigan Contract to Direct Employee 12/1985-12/1996

Manager Quality Assurance and Customer Quality

Supervised a three-shift 37 technician's high speed injection molding and assembly production operation.

Responsibilities: APQP and PPAP Develop Procedures and Standards for the quality control of both automotive and non-automotive components. Lead Product Development Teams and external Supplier Development Teams with the product development and execute audits of company policies and procedures.

Supervised incoming, in process and final inspection to maintain the quality and control of components, sub-assemblies and final assemblies. Automotive and nonautomotive components medical devices and appliances.

Included Prototype, Pre-Production, and Production components and assemblies.

Coordinate and lead the following activities: FMEA (Design & Process), GD&T, MSA, Control Plans, Error/Mistake Proofing, Engineering development and testing, Analyzed DVP&R test results and made appropriate changes.

Lead and Responsible for Certification to the QS-9000 consists of the following basic steps: 1) Review of the QS9000 document standard and its support literature and software; 2) Organizational preparation and assembly of a team that will oversee the certification; 3) Development of a Quality Manual that meets the QS-9000 requirements; 4) Development of support documents for your Quality Manual; 5) Implementation of the quality management systems defined in your Quality Manual; 6) Pre-assessment of your quality systems (optional); 7) Certification to the QS-9000; 8) Continual assessment of your quality systems against QS-9000 requirements to maintain your registration.

ACCOMPLISHMENTS:

•Customer support relationship increased business ten percent (10%) per year and upward to fifty percent (50%) by the fifth year which doubled the business at PSI.

•Develop train and implement procedures for structured, systematic approaches to manage on-site Manufacturing and Supplier Quality. The new Quality System began to monitor and/or control the quality level of production components being supplied by preferred suppliers.

•The new Quality System proved itself to be a success within ninety (90) days with a twenty (20%) increase in productivity and a direct reduction in manufacturing downtime.

•Quality System developing the Plants and Supplier Development with Quality Policies, Procedures, Product Requirements, Roles and Responsibilities.

EDUCATION

Masters of Science - Engineering, Industrial Manufacturing & Quality, 1997, Eastern Michigan University, Ypsilanti, MI.

Bachelors of Science - Math and Chemistry, 1995, Oakland University, Rochester, MI.



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