Quality Assurance Engineer

Efficient in Root Cause and Corrective Action analysis, MRB, and Continuous Improvements in a manufacturing environment.

Proven relationship building with customers and suppliers.

ell versed with Internal and External Audits and maintenance of the quality systems ISO 9001:2015, AS 9100D:2016 and ISO 14001:2015.

Demonstrated skills in leading teams investigating causes of product failure and nonconformances and streamlining the manufacturing processes with optimal solutions through mentoring, coaching, and influencing.

Experience in application of quality/process improvement tools including GR&R; GD&T, PPAP, FAI, MSA, APQP, IPDS, DOE, RCCA, QFD, TQM, FMEA, Kaizen, Lean Manufacturing and SPC. Certified in Six Sigma Green Belt and DFSS.

Familiar with the manufacturing processes: Machining, Heat Treatment, Plating and Painting, Casting, Electrical and Electronics equipment integration (including PCBs) and testing, Fabrication of Electronics Cabinets and Enclosures, RF Communication hardware and systems, Harnesses manufacturing and testing.

Special Achievements

As a lecturer, guided Conestoga College students to successfully complete their quality assurance projects (several dozens of projects over a period of 12 years).

Taught Greenbelt and DFSS students (353 engineers and support personnel over 16 training waves) at Honeywell Mississauga and helped prepare courses for the workshops.

Chaired and resolved several dozens of complex MRBs and FRBs (supplier induced and internal non-conformances) at Honeywell Cambridge and provided comprehensive Quality Notes with completed Failure analysis reports and meeting minutes to customers. The timely resolve helped deliver the programs (Commercial Satellite communication Systems and Hardware) on time or ahead of schedule, achieving greater than 95% supplier quality score from customers (e.g. Boeing, Orbital, etc.)

Championed 5S and eCATS as part of continuous improvement initiatives at Honeywell Cambridge.

Received recognition for improving TRR and PSR processes, which were proven with SES 8 program, resulted in excellent customer (Orbital and SES) management and smooth and satisfactory delivery of program hardware.

Received Bronze medal for dedication to supporting delivery of SES 16 program earlier than customer expectations. The program was on a critical path and had several quality issues.

Single-handedly, while working with customer engineers and a supplier at the same time, managed the final test campaign of space sensors at supplier site, over a continuous period of five days (during Christmas holidays). The test data review and interpretation, acceptance of test results and subsequent final inspection during this period were successful. This intense exercise resulted in on-time delivery and acceptance of hardware by the customer (Boeing) during the absence of the program’s key team members.

Green Belt project “Reduction in scrap rate of Sauereisen filled Temperature sensors” resulted in reduction of 50% scrap rate and improving OTD time with no short orders. Quality tools such as Process Mapping, PFMEA, MSA were used to complete the project.

Business History

Personal Sabbatical Private break for family and traveling 2017 – 2018

Product Assurance Honeywell (COM DEV) Aerospace 2005 – 2017

Program Manager Cambridge, Ontario

Quality Advocate Honeywell (Allied Signal) Aerospace 1997 – 2005

Mississauga, Ontario

Honeywell (COM DEV) Aerospace

Engaged in the design and manufacture of RF components and systems for commercial communication satellites.

Reviewed and analyzed customer contracts (including SOW, Contract, Product & Environmental Specifications, Product and Quality Assurance specifications, Engineering Drawings and other related clauses). Provided inputs to Compliance Documents and formulated flow down of customer requirements to the organisation and initiated the required changes to the existing processes to be compliant.

Participated in review and approval of Engineering documents (ECNs, RFDs, RFWs, Drawings, BOMs, Qualification Plans and reports, Acceptance Test Plans and Test Reports, Reliability and Parts plans and analysis reports, etc.)

Participated in new program for Risk assessment and mitigation and lessons learned phases.

Participated and led, at times, the weekly customer program meetings providing the status of the pending actions and the program progress including quality and components flow issues.

As MRB/FRB Chair, led cross-sectional teams (including SMEs) resolving quality issues with the identification of underlying causes and determination of effective corrective actions.

In liaison with the customer, managed the product assurance program for the awarded programs from the bidding phase to the delivery phase. Participated in program reviews (including PDR, CDR, MRR, TRR and PSR), weekly program meetings and IPDS phase Gates. With the collaboration of other related departments (Engineering, Project Management, Manufacturing Engineering, Procurement, DI Engineering, Drafting, Manufacturing Facility managers, Test Engineering, Planning etc.) completed APQP for new programs.

Organised and led FRB/MRB meetings with the customer including completion and deliverance of the NCR/QN reports including detailed failure investigation reports along with analysis, conclusions and status of corrective actions implementation.

Supported Continuous improvement process sponsored by the respective departmental managers. Using creativity, resourcefulness and analytical skills proposed solutions to persistent bottlenecks enhancing product yield. Participated in lean manufacturing practices improving the processes. Championed 5S and trained other team members.

Honeywell (Allied Signal) Aerospace

Engaged in the design and manufacture of Power Management and Environmental Control Systems for the commercial and military aircrafts, as well the actuations systems for aerospace hardware.

Generated and monitored Quality/Product Assurance Plan. Initiated, upgraded and implemented Quality policies and procedures including second and third level documents. Participated in implementing and maintaining quality systems to the requirements of ISO 9001 and AS 9100 and helped the external audits (Customer and the Registrars) to completion.

Participated in development of APQP / IPDS for new programs launch.

Provided the inputs to development of the manufacturing and assembly procedures (MAP) for all subassemblies and assemblies for aerospace and space products

Conducted internal and external audits determining the effectiveness of the quality systems. Detected and reported deviations to management from the established quality system requirements and helped in the.

Supported customer and registrar audits and lead the implementation of corrective actions identified by the external auditors.

Performed on-site Supplier Assessments and Certifications audits. Recommended suppliers of process improvements to reduce cost and improve delivery without compromising quality. Completed the review of PPAP and FAI reports and documentation and gave the feedback to the management and supplier with recommendations.

Chaired the CAB meetings, help determine the optimal solutions, maintained the actions log and provided the status of the CAB actions to management and stakeholders.

Developed SPC charts and KPI monitoring matrices as part of the NPI initiatives.

Having thorough knowledge in the manufacturing processes (machining, soldering, harnesses, fastening, torqueing, plating and painting, metal fabrication, and casting, etc.), implemented improvement in various manufacturing processes using PFMEA, RCCA, 8D, MSA and DOE quality tools.

Education

Bachelor of Engineering (BEng), Mechanical Engineering, Minor in Industrial Engineering,

Concordia University, Montreal, QC

Mechatronics Conestoga College, Kitchener, ON

Professional Development / Certifications

Six Sigma Green Belt and Design for Six Sigma (DFSS)

Kaizen and Lean Manufacturing

Lead Auditor (BSI)

ISO 9001:2015 AS 9100D:2016 ISO 14001:2015

DOE RCCA QFD TQM PFMEA DFMA SPC MSA 8D IPDS PPAP APQP

SAP and MS Office applications including Word, Excel, Power Point and Visio

Security Clearance: NASA Secret Level and CGP

Professional Affiliations

Professional Engineers of Ontario (PEO)

Senior Member of American Society of Quality (ASQ)

Other Skills (Coaching)

Taught TQM and Quality Assurance courses at Conestoga College for 12 years.

Delivered Six Sigma plus courses to Green Belt and DFSS students at Honeywell.

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