Manager Engineer

Wesley Sylvester

Quality Professional

Huntsville, AL

***************@*****.*** - 256-***-****

An experienced Quality Engineer and Certified New Product Development Professional with proven results and

strong track record of helping companies shorten the time -to-profitability on new product introductions. Honest,

trustworthy and committed to add value by maximizing organizational efficiency, innovation and customer

satisfaction, he has shown adaptability and accountability in both permanent and contract Quality Assurance

assignments in a variety of business segments.

WORK EXPERIENCE

SUPPLIER QUALITY CONSULTANT

HONDA Manufacturing of Alabama - Lincoln, AL - October 2012 to Present

Responsibilities

- Contract assignment for New Model Development support and Design Release for electrical components and

systems. Specific part responsibilities include Electronic Control Units, Wire Harnesses, Washer Systems and

Sensors. Responsible for evaluation of designs, analysis, development, testing and control of major projects of

supplied parts during new vehicle development and mass production launch. Provides Quality and Purchasing

direction for new product development and manufacturing readiness.

SR. DEPARTMENT MANAGER, PQA

SHARP ELECTRONICS, Solar Division - Memphis, TN - August 2011 to Present

- Plans, coordinates and directs solar module quality assurance program designed to ensure continuous

production consistent with established standards. Develops and analyzes statistical data and production

specifications to determine present standards and establish proposed quality and reliability expectancy of

finished product. Formulates and maintains quality assurance objectives and coordinates objectives with

production procedures in cooperation with plant manager to maximize product reliability and minimize costs.

Manages 13 direct reports engaged in inspection and testing activities to ensure continuous control over

materials, facilities, and products. Plans, promotes and organizes training activities related to solar module

quality and reliability.

ADVANCED QUALITY ENGINEER

JOHNSON CONTROLS - Birmingham, AL - May 2011 to August 2011

- Corporate contract assignment Implements corporate quality model improvement initiatives Provides training,

leadership and relationship building Manages and monitors the use of PFMEA, Control Plans, Gage R & R,

Capability Studies, PPAP, APQP, Standardized Work Instructions, Lessons Learned Define implementation

plans and develops procedures & standards to define quality system improvements Develops, implements,

and monitors a Closed Loop quality system to ensure appropriate analysis, corrective action, documentation,

and implementation of solutions to quality system Flexible and determined product launch problem solver for

Kia and Mercedes-Benz.

SR. QUALITY ENGINEER

DRS Technologies - Huntsville, AL - 2006 to 2011

- Created a new Stage -Gate process structure and deliverables for New Product Development by harvesting

best practices from unrelated industries Performance review quote from manager: "Wesley is extremely

intelligent." Support multiple diagnostic, test and energy management system programs for combat vehicles

and weapon systems Provide lead role in developing and implementing project specific QA initiatives in New

Product Development Review and approve drawings, project plans, interface documents and schematics

Participate in design reviews, supplier surveys and selections, test surveillance, CMMI Work Product Auditing

ISO9001, CAPA, Control of Nonconforming Material (MRB), FRACAS Drive Lean/Continuous Improvement

Methodologies, Environmental Test Methods.

INDEPENDENT CONSULTANT

NASA US National Aeronautics & Space Administration - Huntsville, AL - June 2006 to September 2006

INDEPENDENT CONTRACTOR - Provided technical support and Quality System surveillance and inspection

during the development of mirror and optical components for James Webb Space Telescope Performed

functions similar to DCMA at subcontractor for Honeywell and GSFC oversight of special processes per NASA-

STD-8739.X series NASA 4-D team building.

QUALITY CONSULTANT - Contract assignment

Defense and Aerospace Systems - Huntsville, AL - 2005 to 2006

1.5 year Revised Quality Management Systems procedures Led Six Sigma/Continuous improvement teams to

achieve cost savings on several projects: Proposals, Supply Chain Management, Failure Analyses, Material

Quoting and Design Reviews Six Sigma projects resulted in profit contribution of $100,000 and the profit

from these improvements were equal to the profit from $1,428,571 in annual sales revenue Performance

review quote from manager: "Wesley is very visionary." CAR coordinator for design, development and

programs Auditor, revised quality procedures and audit checklists for ISO, AS and TL quality system

compliance Produced Quality Plans and Preferred supplier plan for Lockheed Martin Proposal inputs for

Thales .Implemented CAPA for Boeing, Northrop Grumman, and Rockwell Collins programs DO-254 optimized

variables, saved money.

DEVELOPMENT QUALITY ENGINEER

TOYOTA - Shiroki Japan - Dalton, GA - 2004 to 2005

- Develop & document comprehensive new product quality plans & procedures by supporting research and

development A3 management process and PDCA Represented quality and regulatory on core design change

and new product development teams as an independent reviewer to ensure effective design process control

NPI for automotive window regulators for Mitsubishi and Toyota Cost savings in gage concept improvements

and vendor selection Solved chronic design and process problems Improved product quality from 3200ppm

to 15ppm within first six months Hoshin Kanri strategic deployment Applied Genchi genbutsu experience over

theory approach to achieve results.

QUALITY MANAGER

VENTURE Industries - Seabrook, NH - 2003 to 2004

- Contract assignment, promoted to Quality Manager Led facility to receive Ford Q1 Quality Award; and

reduced Cost of Quality by 50% by exiting General Motors CS2 and reducing debits Cost savings profit

contribution of $75,000 equaled the profit from $750,000 annual equivalent sales 8D Improved process yields

Cost efficient error proofing Performance review quote from manager: "Wesley's preparation is phenomenal."

Injection molded and painted exterior trim Supplier Quality and customer support Control Plans, FMEA, PPAP

The ISO/TS16949:2002 management representative Shainin quality and reliability techniques GP-9, GP-12,

MSA audits.

SR. QUALITY ENGINEER

TOMKINS, PLC - Gates Rubber Company - Auburn, ME - 2001 to 2003

Program Quality Engineer for GM, Ford and Daimler-Chrysler programs PPAP, APQP, Gage R&R, GP-9 Run

@ Rates, Design Assurance nonwoven, thermoformed automotive interior trim 8-D and 5 phase root cause

analysis corrective and preventive actions DV, PV Managed fiber, plastics commodity Suppliers GP-12 Poka

Yokes Attained 0 PPM for several parts supplied to GM Performance review quote from manager: "Wesley is

extremely knowledgeable of automotive quality principles."

DESIGN QUALITY ENGINEER-Contract assignment

TOMKINS, PLC - Gates Rubber Company - Framingham, MA - April 2001 to November 2001

Managed R & D activities and design level corrective action for line and field issues Led several major

Audio Amplifier programs in Design and Process Validation and Reliability for high end North America,

Europe and Japanese automotive markets Developed and implemented Electronic, EMC/EMI, Mechanical

and Environmental Design Validation Test Plans SMT Digital Signal Processing Successful PPAP submittals

and product launches .Engineering change control and project mgmt.

QUALITY ENGINEERING MANAGER-Contract assignment

FREUDENBERG - NOK - Manchester, NH - August 2000 to April 2001

Manchester, New Hampshire QUALITY ENGINEERING MANAGER-Contract assignment, promoted to

Quality Manager Reported to the General Manager Attained PPM objectives for customer returns, warranty and

end-of-line rejects Suspension and Vibration auto components QS9000 Mgmt Rep, UL audits Saved $500,000

on QA budget. Mentored 12 direct reports DMAIC, Six Sigma Greenbelt Received prestigious Shingo Prize

for manufacturing excellence and Chrysler Gold Pentastar Award Performance review quote from manager:

"Wesley is full of ideas."

QUALITY CONSULTANT-Contract assignment

MOTOROLA, Next Level Communications - Rohnert Park, CA - January 2000 to August 2000

Improved process yields by 35% within six weeks for SMT electronics line Photonics, Fiber Optics, Lasers, Ball

Grid Array, ASIC DSL, Set Top Boxes providing voice, high speed internet, and multimedia digital video for

the Broadband telecommunications industry selected inspection points, implemented SPC on SMT processes

IPC-610 certified Subcontractor development and relationship building.

SUPPLIER QUALITY MANAGER

TAKATA, Irvin Automotive - Greenwood, MS - 1999 to 2000

- Implemented Supplier Cost Recovery program resulting in $250,000 annual profit contribution The profit

from this program was equal to the profit from $4,166,667 in annual sales revenue, or $12,333,333 in total

sales equivalency over three years Managed Supplier base commodities of plastics, textiles, leather, stamped

and machined metals and urethane resin Program QE providing APQP, PPAP, SPC, DOE for Interior Trim

products such as visors, armrests and tonneau covers to GM, Ford, Honda, Nissan and Toyota A3 and PDCA

Eliminated top five customer complaints within first six months.

R & D QUALITY ENGINEER-Contract

MAGNA, International - Eastman, GA - 1998 to 1999

served as R & D Quality Engineer $175K cost savings on cut and sew process improvements Ensured

the conversion of customer or product requirements into systems solutions that acknowledged technical,

schedule, and cost constraints Created successful PPAP, validation, and product launch of tonneau covers

and convertible tops for GM successful CS2 exit strategy 35% scrap reduction .Determined inspection points

in process and verification methods.

SR. QUALITY ENGINEER

JOHN DEERE - Fargo, ND - 1996 to 1998

Wrote quality procedures and achieved ISO 9001 certification with TUV registrar Organization development

Establish and implement quality requirements from prototype stage through the end of lifecycle Discrete, SMT

Electronics PDR, CDR Black box Software QA peer reviews Embedded controls for engines, transmissions

and electro-hydraulics customers included Deere, Ford New Holland, Valmont, Rockwell and Case.

SR. CUSTOMER QUALITY ENGINEER

STANLEY ELECTRIC COMPANY - Battle Creek, MI - 1993 to 1996

--Successful new product development of Xerox User Interface Panels; Ford, Toyota, Honda and GM heater

controllers and vehicle lighting systems Hoshin QA tactical team leader VSM Six Sigma Quality, Kaizen,

Kaikaku projects SMED QS 9000 PPAP, APQP, Cpk, FMEA, Control Plans 5S QFD Liquid Crystal Displays,

LEDs, and Surface Mount electronic PCBs PDCA problem solving.

PROGRAM QUALITY ENGINEER-Contract Assignment

GUARDIAN INDUSTRIES, Optical Imaging Systems - Northville, MI - 1992 to 1993

New Product Development and process control of Active Matrix Flat Panel Displays for F-16and F-18 aircraft

cockpits PDCA Wrote Quality Program Plans per SOW PRB/MRB GIDEP alerts FRACAS closures Performed

Supplier facility surveys per MIL-Q-9858 and MIL-I-45208 Mil-Std-2000 trained in Kepner - Tregoe problem

solving.

SUPPLIER QUALITY COORDINATOR

TRW, Space & Electronics Group - 1986 to 1992

--Provided comprehensive Quality Engineering support during all phases of major subcontract development

of satellite systems Telemetry, Electronics including solar cells, gyros; Station-keeping Propulsion including

valves and pressure regulators Section Supervisor for 23 field QEs Deployed and determined workload

assignments In-process, precap, SEM, radiograph, NDT, and source inspections on class S Hybrid and

ASIC devices Secret Security Clearance Hubble Space Telescope TDRSS MilStar NASA Quality System

NHB5300.4 (1B,1C,1D-1) Supplier Surveys Section Trainer for SEM and IC inspection MIL-Q-9858 vendor

facility surveys.

QUALITY ENGINEER

LORAL - Space Systems - San Jose, CA - 1985 to 1986

QUALITY ENGINEER--New Product Development of Space qualified GaAs FET amplifiers and MMICs for C

band and Ku band Satellite Transponders, and RF communication payload products MMIC Circuit technology

SEM/EDX analyses and Material Science support Directed audit program per MIL-STD-1772, MIL-STD 217

for Semiconductor WaferFab, planar processes ESD DD250 submittals and approvals.

ASSISTANT QUALITY MANAGER

AYDIN, Radar & Early Warning Division - San Jose, CA - 1984 to 1985

--Reduced internal and external failure costs by 25% The profit contribution was equal to the profit from

$357,143 in annual sales revenue Cycle time management Measured S parameters for 3-D Radar Research

and Development MIL-Q-9858 Anechoic chamber EMI/EMC testing PRB and MRB per MIL-STD-1520 High

power Transformers and Magnetics, Switches, Isolator, Coupler, Band-pass Filters, Radar/RF devices.

SR. RELIABILITY TECHNICIAN-Secret Security Clearance

TRW, Space & Electronics Group - Sunnyvale, CA - 1982 to 1984

Conducted failure investigations on RF Hybrid microcircuits per MIL-STD-781, MIL-STD-750 and MIL-STD-883

Performed Scan Electron Microscope and Energy Dispersive X-Ray Elemental Analyses (SEM/EDX) of

semiconductor devices DCAS government liaison Corrective and preventive action and recurrence control

thin/thick film and IC fabrication.

ELECTRONIC TECHNICIAN

US NAVY - 1976 to 1982

Performed troubleshooting to the component level and parametric performance optimization of Advanced

RADAR, TACAN, IFF, Satellite, RF Communication Systems and Defense Technologies.

EDUCATION

Navy Advanced Electronics

US Navy - San Diego, CA

Quality Management

San Diego City College - San Diego, CA

SKILLS

Certified New Product Development Professional - PDMA

ADDITIONAL INFORMATION

Certified New Product Development Professional - (NPDP) from PDMA

Created cost savings proposal for $1,500,000 equal to profit from $25,000,000 annual sales

Top five strengths: Intellection, Strategic, Learner, Input, Deliberative - "Strength Finders"

Aerospace and Defense, Electronics, Automotive, Telecommunications industries experience

Over 25 years QE experience planning and launching successful, high quality products

Comprehensive Supplier Development support per Contract and Statement of Work

Analytical tools such as PPAP, FMEA, SPC, 8-D, DOE, APQP, QFD, A3 and PDCA

As Quality Manager received prestigious Shingo award for manufacturing excellence

Familiar with MIL-STDs, NHB 5300.4(1B, 1C, 1D) ISO 9001, TS16949, TL9000, AS9100

Implemented Supplier Cost Recovery program equal to the profit from $4,166,667 in sales

Six Sigma Black Belt participated in breakthrough and continuous improvement projects

Experienced in Japanese knowledge creating cultures and organization development

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