Quality Engineer Manager

NORM COOTS

**** **** ***** ************, ******* 46229

317-***-**** *********@*******.***

Lean Six Sigma Master Black Belt, ASQ Certified Quality Engineer, Shainin Red X Master

Highly-effective technical leader with a history of using Lean principles to create process-flow maps and minimize waste as well as using the Six Sigma and Shainin principles to understand process capabilities and variation, thus driving continuous improvements to achieve performance goals and increase revenue.

Accomplished problem solving expert, leader and manager with over 28 years experience positively impacting the performance of companies through providing coaching to those involved in the application and engagement with the tools and concepts of Lean, Six Sigma and Shainin.

Analytic and strategic expert specialized in building, managing and leading strong cross-functional, cross-cultural teams to improve productivity for manufacturing processes.

Product / Project Management Root Cause Analysis Executive Presentations Process Analysis & Improvement

Quality Improvement Manufacturing Integration Continuous Improvement Internal and External Quality Audits

Customer Enthusiasm Cost Avoidance Capital Equipment Acquisition Team Leadership / Training / Coaching

Lean / Six Sigma Implementation Under Budget Cap Measurement System Evaluation

Taught and Coached 75+ Professionals to Six Sigma Green Belt, Black Belt, and Shainin Journeyman Certifications

Managed Operators, Technicians, Engineers, and Volunteers at Delphi, Remy, EnerDel, and Success Beyond Schools.

Kaizen Events 7 Forms of Waste 5S 8D Problem Solving Value Analysis Talking to the Parts on Plant Floor

Data Analysis (Minitab) SPC and Control Charts FMEA Measurement System Evaluation Process Capability

APQP PPAP GD&T PFD Control Plans 5 Why Full / Fractional Factorial Experiments Returned Part Review

Standard Work Instructions Step-By-Step Problem Solving Manual for Data Collection and Problem Coaching

PROFESSIONAL EXPERIENCE

Practical Cost Reduction, Limited, Indianapolis, Indiana January 2014 – Present

PCR is a firm co-owned by myself and my wife specializing in quality and medical consulting.

Quality and Problem Solving Consultant / Trainer

Major Accomplishments:

Tutor for students taking American Society for Quality Six Sigma Green Belt Certifications.

Trainer, both on-line and in person, for iCert Global for their Lean Six Sigma Green Belt and Black Belt certification programs, teaching students from manufacturing, healthcare, human resources, and other professions.

Contracted by Ingram Micro Mobility to create and write their Six Sigma Yellow Belt and Green Belt certification programs.

Performed data analysis by reviewing the quality of published data and created charts and tables for government submission for nonprofit organization Success Beyond School.

EnerDel, Indianapolis, Indiana April 2010 – August 2013, June 2014 – December 2014 (corporate layoff due to loss of funding)

Formed from Ener1 and Delphi, EnerDel makes Lithium Ion battery packs for consumer and commercial usage.

Quality Engineer and Shainin / Six Sigma Coach

Brought in to help with start of production of EnerDel EV cell, specifically electrode fabrication. Worked with Industrial Engineering, Manufacturing Engineering, and Cost Improvement Team. Became Quality Engineer for electrodes and monitored PPAP requirements for anode, specifically work instructions and other documentation.

Major Accomplishments:

Designed experiments and analyzed data to verify and streamline development of cathode and anode. Provided structure to development experiments that had been lacking. Increased production volumes 10 fold by showing how the experiments linked to each other.

Worked with suppliers on shelf life of raw chemicals, powders, and foils for best output without buying replacement material.

Researched proper documentation, including ISO, TS, and material property sheets, for use in experiments.

Integrated R&D results into production validation, including chemical and welding analysis.

Wrote and conducted process capability workshops for manufacturing, quality, and product engineers.

Sourced, created, and taught Six Sigma Black Belt certification courses for Quality Engineers, based on American Society for Quality (ASQ) certification requirements and budget restrictions. Coached not only all QE’s to Black Belt certification but also immediate supervisor (VP of Quality and Document Control) to ASQ certified Quality Manager.

Used Lean techniques to improve part flow between plants, eliminating 30 hours of waiting and staffing third shift.

Analyzed shelf life effects of EnerDel Korea electrodes on Indiana batteries and found ways to improve throughput and increase sale price with minor production schedule changes. Most of the experiments done in Project Azure (Korean shelf life) were reviewed weekly with CEO, CFO, Korean management, and most VP’s to show progress on the largest production project (excess of $10 million).

Supervised and managed work schedules for four quality technicians to support PV builds, including sampling and testing plans. Used Control Charts to show significant process improvements.

Led FMEA / Control Plan / PFD reviews for production process ramp-up.

Reviewed supplier PPAP submissions and determined what level of warrant required.

Served as “eye of the needle” for all customer returned part tear down analysis.

Wrote standard work instructions and trained quality technicians on proper measurement procedures for chemical, material, and electrical testing. Included mass spectrometry, pull tests, and electrolyte soak test.

Streamlined gage calibration process and leaned out inspection area.

TRW, Lafayette, Indiana March 2014 – June 2014 (temporary job during EnerDel layoff)

Senior Quality Engineer

Responsible for quality assignments in regard to new Ford steering gear line, including Gage R&R studies and work instructions. Also created go/no go masters for production cells for improved quality control.

Remy International, Pendleton, Indiana January 2007 – December 2008 (corporate layoff and restructuring)

Remy International, a spin-off of Delphi Automotive, employs 6,000 people, and earns $1B in sales annually.

Corporate Manager, Performance Improvement

Provided leadership, support and training to engineers, staff, management and directors, instructing them on using problem solving strategies, based on Six Sigma and Shainin tools. Assessed and reviewed customer, product and operational issues, and then headed multiple problem solving projects, including validation test improvements, design issues and manufacturing process improvements, to properly address those issues and enhance operational performance. Managed, collaborated and communicated with global employees to monitor project status and coordinate problem solving efforts across a globally-diverse environment.

Major Accomplishments:

Streamlined procedures by designing, authoring, planning and implementing problem solving resources and tools used by all staff members on site.

Restructured training classes, authoring new documentation and manuals, based on Six Sigma and Shainin principles to more efficiently train staff on using highly successful problem solving and process improvement procedures. Resulted in 25 professionals from different functions becoming Six Sigma Black Belts.

Reduced costs $4M by optimizing warranty procedures to identify root causes, minimize waste and ensure customer policy compliance. Data analysis helped better allocate engineers’ time on projects affecting warranty.

Reviewed other plants’ shipping performance with CEO using Control Charts to show trends.

Interfaced and communicated with suppliers to successfully launch new diode packs, which involved eliminating waste, executing strategically planned procedures and stabilizing system. Fed back design and test requirements for diodes to Remy engineering and Chinese supplier.

Worked with design engineers on reliability testing, including test to failure comparisons.

Led problem solving on new hybrid SUV alternator launch in Mexico plant to meet customer schedule and quality requirements as detailed in APQP documentations.

Served on Advisory Board at Ball State as corporate Master Black Belt, specifically to advise on course requirements, curriculum, job placement and project selection for students seeking minor in Process Improvement.

Delphi Automotive, Anderson, Indiana 1991 – 2006 (corporate layoff and restructuring)

Delphi Automotive, a spin-off of GM, is the largest automotive component supplier in the world.

Supplier Development Engineer 1999 - 2006

Streamlined and optimized several operational procedures by improving product development and manufacturing. Managed and directed quality improvement efforts for the suppliers. Identified and removed root causes using principles from Six Sigma, Lean, Shainin, and other highly recognized purchasing and quality resources. Managed global resourcing project, ensuring all issues were resolved. Served as lead problem solver in issues concerning quality, warranty and purchasing. Established and maintained quality relations with various departments, serving as liaison to synchronize operations, promote constant communication and improve business performance.

Major Accomplishments:

Trained and instructed employees, suppliers and engineers on using various problem solving strategies based on Shainin and Six Sigma principles on site at various national and worldwide facilities.

Main problem solver for Delphi Energy and Chassis division’s Supply Quality function, especially Indiana, Michigan, Ohio, and New York, with other responsibilities at suppliers worldwide. Travel time up to 80%.

Significantly lowered scrap at supplier from 25% to 19 parts per million by optimizing procedures and preventing massive vehicle recall. Problem solution also involved shifting the mean for casting hardness and creating new measurement system while working with materials Subject Matter Experts.

Assessed and reviewed business plan to develop innovative process for supplier selection, thereby enhancing operational performance and increasing revenue. Using Pareto analysis, chose suppliers that had not shown up on individual Delphi plant metrics but had systemic problems for all supplied plants (mixed shipments, delays in shipping, warranty and plant quality issues).

Chosen for and completed Six Sigma training for Black Belt certification, as well as Master Black Belt certification.

Trained and motivated dozens of employees to achieve various certifications, including Six Sigma Green Belt, Six Sigma Black Belt, Six Sigma Master Black Belt, Shainin Apprentice, Shainin Journeyman, and Shainin Master. Candidates included peers as well direct supervisor and Purchasing Director.

Wrote and taught not only own blended problem solving training but also training for all levels of Six Sigma belts, researching and working with other Master Black Belt peers.

Process Engineer / Quality Engineer 1991 - 1999

Planned, designed and implemented conveyor system and equipment layout, as well as managing installation of supplementary assembly line. Chosen as member of dedicated scrap reduction team to solve perennial scrap problems which were causing material scrap, production overtime, and poor field warranty.

Major Accomplishments:

Successfully eliminated 90% of scrap waste within one year by implementing the use of Shainin problem solving principles, which also reduced costs in overtime and production and increased productivity. Involved not only root cause analysis of cracking of diodes but also redesigning electrical testing and probing (testing reverse currents in units of nanoamps under various environmental situations).

Earned certification as Shainin Apprentice and Journeyman.

Selected to attend and acquire Shainin Master training, becoming one of Shainin LLC’s first certified Masters.

Acquired GM trade secret for cracked diode containment procedure, and then assessed, identified and eliminated cracked diode chips issue, resulting in a lowered scrap price from $3.50 each piece to $0.35 each piece.

EDUCATION / TRAINING

Bachelors of Science, Mechanical Engineering

Purdue University, West Lafayette, Indiana

Bachelors of Science, Physics and Engineering Science

Manchester College, North Manchester, Indiana

PROFICIENCIES

MS Office (Advanced user of Word, Excel, PowerPoint)

Minitab Statistical Software

CERTIFICATIONS

Six Sigma Master Black Belt (Delphi / AIT Group)

Six Sigma Black Belt (Delphi / AIT Group)

Six Sigma Black Belt (Six Sigma Management Institute)

Six Sigma Green Belt (American Society for Quality)

Six Sigma Green Belt (iCert Global)

Shainin Red X Master (Shainin LLC)

Certified Quality Engineer (American Society for Quality)

Senior Member (American Society for Quality)

COMMUNITY PROGRAMS

Six Sigma Program Advisory Board Member (Ball State University)

Six Sigma Wings for Heroes Coach for Veterans Wanting Six Sigma Certification

Success Beyond Schools Non-Profit Corporation

TECHNICAL SUMMARY

Wide-ranging knowledge of problem solving strategies includes deep exposure to Lean, Six Sigma, Shainin and Quality and Purchasing principles, resources and tools.

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