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Engineer Quality

Mauldin, SC, 29662
March 06, 2019

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Michael A. Morelli

Senior Quality Engineer

*** ********* ****, ************, ** 29680 864-***-****

A results – oriented business professional with proven abilities in strategic planning, managing projects, improving efficiency of operations, team building, and detailing project information to determine effective processes for operations. Able to identify areas of strength and weakness and implement company policies, standards, changes in operation, and systems that optimize productivity and bottom line. Demonstrated ability to motivate staff to maximum productivity and control costs through the most effective uses of manpower and available resources.

Professional Experience

Senior Quality Engineer

Proper Polymers – Automotive Class A injection molding for BMW Piedmont, SC

2018-2018 Nov

Reduced launch 3rd party inspection by 40% due to training and updating of operator instructions

Reduced PPM by 25% by using customer liaison activities to analyze important issues and implement corrective actions

Led all cross functional teams to answer customer 8D’s improving closure rate from 10% to 85%

Updated and improved all operator instructions to a more visual format resulting in a 70% reduction in internal PPM.

Lead all internal and external cross-functional teams for problem-solving in corrective action.

Customer interface for all external\internal issues and PPAP.

Senior Quality Engineer

Kongsberg Automotive – Automotive Fluid Systems Easley, SC


Ensured the supply base adhered to KBD/NPI process thru APQP process

Improved supply base performance thru on-site run@rate or process audits

Worked jointly with procurement performing risk assessments

Developed and implemented inspection protocol at supply base to eliminate incoming inspection

Performed and reported out supplier performance thru audits and business reviews

Quality Process Improvement Engineer

Magna Mirrors, NA – Mirror assemblies for Mercedes Benz and BMW Greer, SC


Created all pre-safe launch instructions for all customers including training and implementation

Improved current quality plans and gauging resulting in a 42% reduction in PPM

Led/monitored corrective action teams for all customers thru root cause analysis –

Reduced incident rate by 60% across all assembly lines

Managed a supply base of 60+ globally which encompassed corrective action and improvement plans

Plant Operations Manager 2011-2013

Operations Manager 2009-2011

Quality Supplier Process Improvement Engineer 2007-2009

Bosal Industries – Automotive Exhausts Lavonia, GA

Facilitated a multi-national plant operation in quality, safety, operations, and leadership resulting in $2million savings annually

Thru lean manufacturing principals, able to sustain YoY savings up to $215K

Conducted weekly meetings with all employees to improvement communication, build a team environment, and improve job performance

70% of productivity improvements were the results of empowered employee participation

Product launches were all within or under budget

Championed scrap reduction teams which resulted in 38% reduction

Project leader for NPI launches including PPAP submissions, FMEA’s, control plans, and standardized work

Quality Supplier Process Improvement Engineer

Honda Trading of America – Automotive Supply Timmonsville, SC


Led supplier development and administration of 45 suppliers

Managed teams for all new model launch activities from design level to mass production

Addressed daily mass production issues for 4 plants worldwide. South Carolina, North Carolina, Taiwan and Thailand

Quality Supplier Process Improvement Engineer

Kaiser Aluminum – Automotive Foundry Greenwood, SC


Engineer responsible for all shop floor and supplier quality activities

Discretionary ability to implement quality decisions on floor, including line stoppages, containment and disposition of material

Operations Manager 1997-2003

Quality Assurance Manager 1996-1997

Quality Supplier Process Improvement Engineer 1995-1996 Piedmont, SC

Drive Automotive – Class A metal stampings for BMW, Mercedes Benz, Ford, Chrysler, and GM

Adjusted production line layouts and resources while maintaining quality and increasing quantity

Increased production by 36% at a cost savings of $75K annually

Established cross-functional teams to identify and implement cost saving initiatives, which yielded savings up to $300K

Assisted in new program cell layouts, development of tooling, and delegated cross training efforts

Employee satisfaction improved from 42% to 71%, increasing employee longevity

Spearhead safety committee that was successful in reducing work related injuries and workman compensation claims

Customer liaison for all quality requirements new and sustaining products

Managed QS9000, Ford Q1, PPAP, SPC systems

Extensive training in Toyota production system, Kaizen, and lean manufacturing

Developed and maintained shop floor management by using visual communication boards

Education and Certifications

Bachelor of Science in Business Administration, Almeda University

Mechanical Engineering Technology, Greenville Technical College

Business Management, St Johns University

Certified Lead Auditor – Automotive ISO 14001, ISO/TS 16949-2009, VDA 6.3, 5P, Calibration, NDT, Positive Management Leadership Program, Interpersonal Communication Skills, Statistical Process Control, APQP, FMEA, Control Plans, Team-Oriented Problem Solving, Managing Fair & Effective Discipline, Toyota Production System, and Train-the-Trainer

Proficient in Microsoft Word, Excel, and PowerPoint

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