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Engineer Quality

Location:
Summerville, South Carolina, United States
Posted:
April 24, 2019

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Resume:

Kazi Ahmed

**** *** **** **, ******, SC-*****

570-***-****(H) / Email: ac8647@r.postjobfree.com

NOTABLE EXPERIENCE:

ASQ certified Six Sigma Black Belt (CSSBB)

ASQ CQE certified Quality Engineer

ASQ CQA Certified Quality Auditor

ASQ Six Sigma Green Belt

Certified G D& T

AS 9100 D Experience

ISO 9001:2015 systems.

NADCAP composite

NDI NADCAP C-Scan

Ultrasonic NDI system qualifications

Boeing qualification of composite processes (BAC 5317, -3, -4, & BAC 5578)

Boeing D1-4426 process approval

First Article Inspection

Supplier & Customer audit

Data Analytics experience

Development quality assurance processes

Quality Control of the products & processes.

Internal Quality audits

New product introduction (NPI) to existing line

Develop documented processes

Measure the key processes indicators (KPI’s)

Establish the quality metrics

A to Z all QC activities.

Systematic Problem Solving (8 –Step).

Implement CI approaches.

Process validation activities.

Experienced with Composite Fabrication and Lab/machine shop and clean Room (CCA)

Product Reject / Defect Investigations & CAPA

Product quality and inspection experience.

Lean Technologies

Aerospace Quality Management Experience

Quality training Experience

Sustaining and maintaining the manufacturing process

Reducing scrap & rework

Knowledgeable IATF 16949:2016

Six Sigma methodologies

Statistical Process Control

Integrated Product teams (IPTs) experience.

Using CMM Equipment

Quality management and surveillance.

APQP, MSA, ISO/TS 16949

Process capability & PDCA

Process DFMEA & PPAP

5 why’s & 8D approaches.

Implement Robust RCCA

Material Review Board(MRB) Delegation

Variation analysis and dimensional management.

Process improvement & tooling experienced.

SUMMARY

More than 20 years of experience as a Quality Control Manager, Continuous Improvement Manager, Manufacturing Engineer, and Quality Control/assurance Engineer in Aerospace Industries for all kinds of precision aluminum alloy metals, composite structural products and assembly parts including Automotive Industries.

Provide the as-built parts configuration to the as-designed configuration for products to meet customer requirements.

Read, Interpret, Analyze & Review Engineering specifications, Blue prints, drawings, designs, CATIA MBD model & PDM products, Customer Standards & Requirements, Customer’s PO (Boeing BAC & BMS Spec, AMS, Bell Spec, BSS Spec, Sikorsky SS Spec, PS, Defense MIL Spec, NAS, MS, ASTM & ASME Spec etc.)

Development and implement ITAR compliance program. Update all documents related to ITAR compliance

Develop, implement and maintain the quality management systems, quality assurance procedures and forms, quality control activities, surveillance audits, customer process & procedures audits.

Maintain the ISO & Aerospace quality systems such as ISO 9001, AS 9100, NADCAP AC 7118 & AC 7114

Manage quality functions, the engineering products assurance, processes and materials to achieve the best quality.

First Article Inspection (FAI) reports per AS 9102. Perform the surveillance audit of suppliers.

Participate internal, external, supplier, and customer quality Audits. Engineering MRB Decisions such as submit, rework, scrap. & use as is. Experience applying processes to engineering development and manufacturing efforts.

Perform root causes analysis, internal and external customer Preventive and Root Cause Corrective action (RCCA).

Plan sequence of operations and specifies procedures for the fabrication of product. Incorporate inspection and test requirements into the production plan.

Investigate and initiate corrective action of problems and deficiencies to ensure product quality.

Implement continuous improvement, Waste elimination tools, Kaizen, 5S, Kanban, pulling system, standard work, Poka-Yoke and Theory of constraints (TOC), Control plans, FMEA & Statistical Process control (SPC),

Perform Statistics, Probability, Statistical Decisions, Hypothesis Testing, Regression analysis, Design of experiments (DOE), ANOVA analysis, Design for Six Sigma (DFSS) methodologies, Parametric and non-parametric tests

Apply Six Sigma DMAIC Methodologies for reducing process variation & improve bottleneck of process.

PROFESSIOAL EXPERIENCE

Quality Control Manager March 2018 – May 2019

DBW fiber Corporation, Summerville, South Carolina

High-temperature, thermal-and acoustic heat shielding products for Automotive Industries

Develop and implement quality management system that support contract requirements and process compliance.

Work as a management quality representative for company. Support company’s policy, regulations and compliance.

Maintain the quality control/assurance management systems and continually improve its effectiveness.

Responsible for completion and submission of APQP and PPAPs quality documents to customers timely.

Perform internal process audit, VDS 6.3 process audit for company capacity and performance and ISO/TS 16949 audits.

Implement all corrective actions for internal and external customers.

Ensuring engineering design records and specification requirements are properly understood and the manufacturing process has the potential to produce product that will consistently meet the requirements during an actual production run.

Establish and sustain internal audit process in compliance with QMS. Maintain the audit readiness and quality awareness.

Perform ISO 9001:2015 surveillance and recertification audit. Maintain and update the KPI’s for company’s processes.

Respond all corrective and preventive actions for internal, external, customers & suppliers audit.

Evaluate and recommends the engineering change proposals of tool. Approve the deviations of tool modification.

Successfully implement new products introduction to existing production line. Establish zero defect free product process.

Provide supervision and technical guidance to the QA staff. Mentor and train employees regarding to quality procedures.

Lead, counsel, coach and provide all technical supports to QC department personnel and others employees.

Company is running out of business and is moving to another country. I got layoffs.

Quality Control /CI Manager October 2014 – February 2018

Tighitco Inc, Ladson, South Carolina

Totally Composites Parts Supplier of Boeing 787, Boeing 737, Spirit Aero systems, & Gulfstream G650 program etc.

Direct, develop and implement quality assurance procedures that support contract requirements and process compliance.

Implement and maintain the quality control/assurance management systems and continually improve its effectiveness.

Evaluate and analyze the current quality assurance processes and its suitability and effectiveness.

Plan, develop and improve the quality assurance activities of new products and services. Change the technical requirement through the engineering configuration management process.

Establish and implement the quality policy and procedures on quality related function for shop floor and other department.

Serve as key technical person for aerospace quality management system. Cost savings (300K) throughout CI projects.

Support, communicate and maintain the company’s mission, quality policies, regulations and customer compliance

Gain Boeing qualification of composite processes (BAC 5317, -3, -4, BAC 5578, BAC5980 & NAS 410 specification).

Achieve Boeing approved processor (D1-4426) and all engineering qualification of special processes and equipment (Ply cutter, core area, CCA& EMA room, OLT, Leaser Guide, autoclave, oven, exterior paints and NDI system etc).

Work with customer qualification documents such as Thermal Profile Plans, Pre-Part Verification Plans, and First Part Qualification (FPQ) Plan accordingly to customer process Specifications.

Ensure complete and timely control of MRB material through Quality clinic and RCCA. Develop the business Plan.

Fully engaging all functional areas and monitoring CI projects activities. Ensuring in completion of CI projects.

Establish and sustain internal audit process in compliance with QMS. Maintain the audit readiness and quality awareness.

Ensure good quality metrics are established, managed and distributed. Cost of Quality, scrap & rework etc.

Fully engage in and monitor continuous improvement activity. Implement Six sigma projects and big cost savings.

Perform ISO 9001:2008 & AS 9100C surveillance, recertification, NADCAP composite and NADCAP NDI audit.

Respond all corrective and preventive actions for internal, external, customers & suppliers audit.

Successfully implement new products introduction to existing production line. Establish zero defect free product process.

Provide assistance in the root causes analysis of non-conformance. Establish process and product improvements.

Oversee the process of problem resolution to ensure effectiveness of the quality management system.

Make ensure the corrective /preventive action plans to assure timely completion. Provide direction for validation of corrective action to assure causes of non-conformance has been eliminated.Validate the effectiveness of RCCA.

Review the approval of quality planning changes or disposition of non-conformance products/processes.

Provides guidance for reviews and validates product non-conformances and disposition type and quality requirements.

Weekly provide scrap reports to GM with alone full analysis of non-conformance of products and processes.

Apply advanced manufacturing engineering approaches to revolve the failure of aerospace product & components.

Plan for necessary steps to perform product testing techniques, tools & procedures including inspection instructions, test requirements and criteria, documentation requirements, compliance requirements, source requirements, and FAI etc.

Experienced with aircraft composite structural parts repair, fabrication and analysis of repaired parts to meet requirement.

Planning, organizing, controlling and facilitating the quality team. Exercise leadership and promote team building.

Provide supervision and technical guidance to the QA staff. Mentor and train employees regarding to quality procedures.

Lead, counsel, coach and provide all technical supports to QC department personnel and others employees.

Position was eliminated due to layoffs.

Quality Control Manager May 2013 – July 20 14

Whitetail Manufacturing Inc., Williston, Vermont

Precision machining components for aviation, defenses, UTC aerospace and Bio-medical etc.

Work as a management quality representative for company. Support company’s policy, regulations and compliance.

Perform ISO 9001:2008 & AS 9100C surveillance audit. Use quality analysis tools and techniques to identify defects.

Implement and maintain the quality management systems and continually improve its effectiveness.

Develop and implement ITAR compliance program. Update all documents related to ITAR compliance. Maintain and uphold company’s quality policy with objective evidences. Respond all corrective actions for external audits, customers & suppliers. Improve outside special processes for sending parts to suppliers. Review customer PO.

Prepare FAI inspection records per AS9102. Manage the planning and execution of product inspecting efforts.

Verify and record all-objective evidence of engineering requirements. Update and calibrate of inspection tools.

Develop better in process-inspection methods in house. Plan, organize and facilitate Quality team as required.

Provide general supervision and technical guidance to the QA staff. Lead, counsel, coach and QA supports to others.

Position was eliminated due to owner family took over my business.

Manufacturing Engineer June 2010 – March 2013

Hexcel Corporation, Pottsville, Pennsylvania

Composites Honeycomb Core, Blade Cells Part for Boeing, Bell, Sikorsky, GKN, GE & ATK.

Provide continuously manufacturing engineering supports, inputs, responses and activities for fabrication all kinds of Honeycomb Cores including metal, non-metal, Nomex, acoustic cores etc. and helicopter blade cells for composite.

Develop, maintain and support effective, efficient and responsive engineering supports for assigned customer programs.

Incorporate changes to specifications and other documents to manage the deployment of materials, parts and processes.

Perform tests to qualify new tools, equipment, materials, parts and processes to meet requirements.

Conduct basic analysis to determine performance or reasons for failures of tools, materials and processes.

Collect information to support the requirements for tooling, equipment, materials, parts and processes used in the manufacturing of composite products. Use project management tools to meet cost, technical and schedule requirements.

Apply LEAN and Quality principles into materials and processes, product qualification, work procedures and lab areas.

Provide technical assistance to manufacturing organizations on advanced tools, materials, processes and equipment.

Develop and implement production and tooling methodologies.

Participate on integrated Product Teams(IPTs) to integrate technical solutions across multiple discipline.

Develop, identify and implement conceptual process designs and maintain the program architecture for build.

Lead and implement manufacturing plans. Conduct producibility and variation analyses to ensure that manufacturing process capability matches requirements. Resolve technical problems of significant impact to perform, cost and schedule.

Coordinate and implement new engineering principles, theories, advanced technologies and concepts. Validate and ensure production readiness of solutions to complex problem. Implement lean principles and technologies.

Develop employees by instilling a “Can Do” attitude, provide adequate training, supports, feedback and opportunities.

Create manufacturing creativity works, implement, monitor and maintain manufacturing (modification) processes.

Improve existing operations & processes incorporating new methods and processes.

Review sale Orders, specifications, and drawings to manufacture a detail, sub-assemblies or assemblies per customer.

Create written instructions and design tools supports to assist in fabrication parts.

Create Bill of Materials (BOM), written process instructions, & make sketches of detail, sub-assemblies and assemblies.

Create statement of work (SOW) for the fabrication of tooling. Provide weekly status to management on status.

Provide creativity by proposing new ideas or finds new and better ways of doing things.

Provide technical recommendations on substantive changes in design development or production plans.

Provide daily support of type part meeting and initiatives. Support manufacturing process though engineering cost estimating, providing new quotation, developing cost reduction process, and successfully new program introduction.

Position was eliminated due to layoffs.

Manufacturing Engineer January 2008 – June 2010

Kaman Aero Structure Corp, Wichita, Kansas

Totally Composites Parts Supplier of Boeing, Bell, Sikorsky, Lockheed & Raytheon, etc.

Fully Support the Manufacturing Engineer Department for making composite aero structural parts and requirements of Composite manufacturing processes.

Responsibility for supporting the design, development, demonstration and transition of innovative composite processes, tooling and technologies to support Boeing programs. Work on implementing of new fabrication technologies into production. Apply details hands –on support of lab and composite production environment including composite process development, composite fabrication, and tooling for composites. Assist in implementing Preventive/corrective action.

Review, create and develop the manufacturing planning to capture all customer's design, drawings and specifications,

Solve and implement long term solutions of composite process related non-conformities thoroughly analyzing existing methods or building new processes. Evaluate and analysis of aerospace production discrepancies for all types.

Prepare and provide the clear & concise fabrication instructions with details description for building composite parts.

Represent engineering on the MRB person, responding to questions and concerns from manufacturing and engineering.

Evaluate engineering/production data to determine corrective actions necessary for the elimination and prevention of chronic errors. Work across all functions to ensure corrective action is implemented.

Apply innovative approaches in process improvement activities and the ability to work with multiple disciplines with engineering, manufacturing and other organization. Work with suppliers and audit MRB activities of suppliers.

Create BOM from customer MBD products, customer's drawings & specifications and put BOM in internal MRP systems.

Work closely with tooling departments for needed any tooling design, trim tools & fixtures, layup tools, and shop aid.

Validation and verification of first run productions of new composite manufacturing process.

Work with customer qualification documents such as Thermal Profile Plans, Pre-Part Verification Plans, and First Part Qualification Plan accordingly to customer process Specifications. Implement new part introduction in process.

Provide and define manufacturing methods and approaches for tool function, laminating development, bagging techniques, autoclave curing, trimming, and inspection. Perform Engineering MRB Decisions.

Analyze and investigate the root causes & corrective action of products non-conformances, and customer returns.

Due to pending layoffs, pursued an opportunity with composite field in Hexcel.

Quality Control Engineer September 2006 – January 2008

Perfekta (Aerospace) Inc., Wichita Kansas

Supplier of Boeing, Raytheon, Spirits, Cessna & Gulf Stream etc.

Define and flow down the requirements of customer’s design, drawings, specifications, and standards for products, and process into the shop floor through job travelers after reviewing the customer's drawings, customer’s Digital Product Definitions (DPD & MBD), specifications, engineering standards, P.O. requirements and contracts.

Verify and record the all-objective evidences of engineering requirements, customer specifications and standards.

Develop the robust system for proving the quality records including FAI reports, C of C and others to customers.

Operate PC-DMIS CMM to inspect parts and quality buy off job traveler’s operation.

Provide technical supports all product acceptance functions to clarify and ensure compliance with quality requirements.

Perform internal audits that all procedures and processes are in compliance with company/contract requirements and process requirements.

Pursued an opportunity with a larger Composites company

Quality Control Engineer January 2006 – September 2006

DJ Engineering (Aerospace) Inc. Augusta, Kansas

Supplier of Boeing, Northrop Grumman, Raytheon, Douglas & Lockheed Martin etc.

Develop better Aerospace AS 9100 quality assurance systems & procedures to increase the company’s quality ratings.

Interpret and read engineering documents, drawings, specifications, requirements, and customer standards.

Implement the continuous improvements approaches to production. Prepare FAI in accordance with AS9102.

Verify and record the all-objective evidences of engineering requirements, customer specifications and standards.

Develop the robust system for proving the quality records including FAI reports, C of C and others to customers.

Operate Zeiss CMM to inspect parts and quality buy off job traveler’s operation. Initiate and implement of preventing and corrective actions. Implement Six Sigma DMAIC methodology to reduce the process variation and improve quality.

Develop the rejection history and source inspections.

Recruited to Perfecta.

Quality Assurance Engineer September 2003- November 2005

Tiercon Industries Inc., Hamilton, On, Canada

Supplier of Canada Aircraft, Bombardier Aerospace and Bell Canada etc.

Review the manufacturing routing, Engineering designs, drawings & specifications, parts lists & purchase order that all quality requirements have been met to exceed the customer expectation.

Prepare the FAI as per AS 9102 Rev-A and working closely with G D &T, Aerospace quality standards and providing Engineering MRB decisions such as submit, rework, scrap. & use as is.

Analyze CAD model using CATIA V5. Provide drawings’ interpretation & design problems, Read & interpret blue prints, Mylar, customer specifications & using measuring devices.

Relocated to USA.

Quality Assistance January 2003 – August 2003

Daimler Chrysler Motor Company, Detroit, Michigan

Help to develop, review and approval of all documentation needed for PPAP, APQP, PFMEA, MSA, production flow and Control plan manufacturing document to ensure good quality process changes for existing products.

Develop internal audit check list accordingly to ISO/TS 16494:2002 (E) and conduct the product and process audit.

Participate in cross-functional team efforts to solve product and or process related problems.

Pursued an opportunity in Canada

Senior Quality Engineer January 1993 - December 1999

Aftab Automotive Bangladesh, Joint venture of Toyota, Japan

Review, develop and approve of APQP, PPAP, PFMEA, and control plan. Determine the root cause of internal process & quality issues. Investigate the root causes and implement corrective action. Verify the corrective action effectiveness.

Manage customer issue through corrective actions, supplier action request and nonconforming material report. Develop and review quality procedures and inspection plans. Planning and conducting of process and systems audits of manufacturing and support departments. Work independently improving cost and quality of processes.

Carry out capability studies to determine capabilities of existing processes.

Relocated to USA.

EDUCATION

MS in Mechanical Engineering, University of Detroit Mercy, Detroit, Michigan, USA, 2002. GPA 3.85

BS in Mechanical Engineering. Bangladesh Engineering University &Technology Bangladesh, 1992.

CERTIFICATIONS

ASQ Certified Six Sigma Black Belt (CSSBB) & Certified Six Sigma Green Belt (CSSGB).

ASQ (American Society of Quality) Certified Quality Engineer (CQE).

ASQ (American Society of Quality) Certified Quality Auditor (CQA).

Composites Engineering Material Courses for Engineers from Wichita State University, Kansas.

Certified Geometric Dimensioning & Tolerancing (G D&T, ASME 14.5 M-2004)

Certified Hexcel Internal Quality Auditor (Accordingly to Aerospace standards AS 9100, Rev- C)

Retrained to Aerospace New Quality System AS 9100 Rev-D.

Fundamental CATIA -5 training courses completed (40 hours)

Certified Quality Management System Lead Auditor (ISO 9001:2015 & ISO 14001:2015).

Status:

US citizen.

COMPUTER SKILLS

CATIA V5, AUTO-CAD, CATIA –V5 DMU, CATIA-V5 ANOVA and Fiber SIM

Cimax / Cyteline and CAS MRP –II software

MRP manufacture software experience (EPICOR MRP, SAP MRP, Business one MRP, and CAS MRP software)

Job scope MRP systems, auditing tools and techniques. Hypermesh, Nastran, LS Dyna and finite elements analysis.

E2 –shop floor MRP systems, FAI Net-inspection

Q-pulse, MINI TAB-16, Advanced MS Word, MS Excel, Excel Macros, MS PowerPoint, Access & MS Visio etc.



Contact this candidate