Manager Quality

Donald B. Morse

*** ***** *****, ******* *******, SC 29316 423-***-**** **********@***.***

Management / Engineering / Manufacturing / Quality

Hands-on and innovative problem solver eliminating waste and reducing variation via continuous process improvement. Well-organized manager with a presence on the manufacturing floor. Meets project and schedule constraints through associate involvement and excellent communication. Skilled facilitator, motivator, and mentor of the Workforce, Engineers and Managers.

AREAS of EXPERTISE

Plant Management

ISO / TS / VDA / AS / IATF

ISO 14001 (EHS) / GD&T

6 Sigma Green Belt/Cont. Improvement

Kaizen / Lean Manufacturing

Supplier Development / Program Mgt.

Statistical Process Control (SPC) / TPS

Customer Service / Technical Service / Sales

Union / Non Union Experience / Focus Factory

P&L / Business & Strategic Planning / Capital Equip.

Team Building / Supervision / Mentoring / Auditing

Project Management / Start-up / Process Flow / SAP

APQP / PPAP / FMEA / Control Plans / OSHA / EPA

Kanban / Part Presentation / OEE / APU / 5S / TPM

Automotive…Aerospace…Tier One…Tier Two… Packaging… Assembly…Service

EXPERIENCE HIGHLIGHTS

Röchling Automotive USA (manufacturer of injection molded / blow molded automotive components)

Quality Manager (Oct 2017 – Mar 2019) Directs a staff of 15 Quality Engineers and Technicians

Successfully moved company from TS-16949 to IATF-16949

Managed safe launch activities for over 100 new products

Developed test scheduling system for new products, reducing outsourced measurement

Developed and implemented Quality Orientation training for onboarding new employees

Led team in the reduction of $300K in customer debits

High Performance Conductors (manufacturer of plated and drawn electrical conductors)

Quality Manager /Quality Engineer (Nov 2015 – Oct 2017 ) Directed staff of eight Quality Engineers and Technicians overseeing all aspects of product quality and customer focus

Completely redesigned and refocused corrective action process, resulting in more robust processes

Resolved lingering customer complaints through teamwork, resulting in better customer relations

Redesigned Material Review Board process, quickly identifying emerging issues

Developed dash-board style metrics system for plant reporting

Gestamp Chattanooga (manufacturer of automotive stampings and welded assemblies)

Quality Manager (July 2014 – Aug 2015) Directed staff of twenty-six technical associates including Supervisors, Quality Engineers, and Technicians involved in the approval and release of product, weld validation, new product startups, and Quality Systems.

Inherited and resolved 28 different build issues at a major customer

Designed product lockdown system to minimize the potential outflow of suspect product

Developed an effective method for supplier monitoring, analysis, and accountability

Kautex, a TEXTRON Company (manufacturer of blow molded automotive fuel systems)

Quality Manager/Focus Factory Manager/Lab Manager/Quality Engineer (Aug 2000 – Apr 2014)

Directed 20 technical associates, including Quality Engineers, Process Engineers, Quality Technicians, and Document Control. Activities included new model launch, testing, Quality Systems, Change Point Management, Standardized Work, assembly, and customer service. Served as Quality Manager at second location and interim Plant Manager at both locations.

Successfully installed the Toyota Production System on all production lines

Reduced department headcount by ~60% increasing efficiency and eliminating waste

Reduced PPM by 300% and drove Supplier PPM to < 10 in ten years as Quality Manager

Championed Engineering Change Control (shop floor Change Point Management) program

Designed Document Control System for Quality Systems and Environmental Management.

Meridian Automotive Systems, (now defunct) (manufacturer of sheet molded outer body components)

Operations Manager, Body Components Focus Factory (2000)

Managed and maintained operational capability of mass production equipment with three supervisors and 75 associates on 3 shifts. Equipment included 17 industrial presses and assembly

Created Focus Factory for new department within the facility.

Implemented lean techniques to reduce operation from seven days per week to five days per week, while taking on additional business and with less operations associates.

Successfully implemented and achieved QS 9000 Quality System certification

Therma-Tru (now Fortune Brands) (manufacturer of residential doors)

Manager of Production / Quality Manager (1999)

Managed and maintained operational capability of high speed assembly equipment with seven supervisors and 150 associates on 3 shifts.

Directed the set-up and staffing of second, independent assembly line.

Directed and managed the complete rebuild of primary assembly line.

Improved internal and external quality ratings by 25%.

Implemented Supplier Improvement Program

RAMCO Manufacturing Company (now defunct) (manufacturer Aluminum extrusions and assemblies, green field site)

Director of Operations / Quality Manager (1992 – 1999)

Managed and maintained operational capability and tooling of mass production equipment with three managers, seven supervisors and 250 associates on 3 shifts.

Revamped production scheduling process, improving customer response time.

Implemented plant wide lean activity, resulting in an $800K gain per month to the bottom line.

Reduced in-process inventory by 90%.

Researched, purchased, set-up, and operated Quality Testing Laboratory

Championed successful ISO-9001 / QS-9000 and Q1 implementation teams

Slater Steels, Inc. (now Valbruna Slater) (manufacturer of stainless, alloy and tool steels)

Steel Mill Manager / Melting Metallurgist (1986 - 1992)

Responsible for all primary and secondary melt activities. Directed nine supervisors and 75 associates in an EAF / AOD facility.

Lowered operating costs by 24%

Reduced melt related defects from 3.0% to 0.4%

Successfully implemented on-line, shop floor reporting system.

Successfully implemented real time, shop floor Statistical Process Control (SPC)

Prior Positions: Republic Steel (now Republic Engineered Steel) General Foreman, Melter, Continuous Casting Metallurgist, Melt Shop Metallurgist, Product and Process Metallurgist, Rotating Shift Metallurgist. (1979 – 1986)

EDUCATION

Bachelor of Science – Materials Engineering

Virginia Polytechnic Institute (Virginia Tech)

REFERENCES AND SALARY HISTORY

Available upon request

Contact this candidate