Engineer Quality

JOSEPH H. LUKAS

** *********** ***** ******.****@***.***

Little Rock, Arkansas 72223 501-***-****

SUMMARY OF QUALIFICATIONS

Experienced in Quality management and engineering

Strong abilities in developing and auditing quality systems

Strong in problem solving and statistical methods

Persistent, detail oriented and act with a sense of urgency

Senior member, American Society for Quality

Certified Six Sigma Green Belt through Emerson Electric

Consultant for two different projects: RCCA & ISO-9001

PROFESSIONAL EXPERIENCE

POWER TECHNOLOGY INC., Alexander, AR 2012 - 2013

Quality Assurance Manager (Severe business downturn)

Products: Lasers and laser power supplies for research, defense, aerospace, medical and commercial applications.

Products ranged from lower end to instrument quality lasers & power supplies, both catalog and custom assemblies.

Responsible for managing and conducting all quality activities in a small, family-owned business. Supervised one

Quality Lead person and one Quality Inspector.

Conducted gap analysis from current state of quality management system to ISO-9001 compliance.

Developed action plans to achieve ISO-9001 registration for both the ISO-9001: 2008 and 2015 standards.

Wrote, revised and implemented procedures and work instructions toward achieving ISO-9001 registration.

Redesigned the production cell monthly incentive plan, which made it more equitable and easier to achieve,

along with promoting important company quality and customer service objectives.

Prepared and presented a monthly quality review attended by all employees. This presentation included all

tracked quality metrics such as internal rejects, warranty returns and on-time shipping.

Completed containment actions, root cause analysis, developed corrective actions, composed and submitted

corrective action reports and answered follow-up questions from customers.

Managed document control system along with the review and approval of all operator build instructions.

Controlled, purchased and calibrated all gauges used for product acceptance.

Developed and conducted training classes for assembly workers on cable and wire harness inspection.

Reduced warranty returns average days in house from 454 days to less than 40 days within 4 months.

DUCOMMUN INC., Berryville, AR 2009 – 2012

Quality Engineer, Ducommun LaBarge Technologies Division (Position eliminated)

Products: High-reliability custom wire harnesses for defense, aerospace, and medical applications used in various

communications, rockets, satellites, military & commercial aviation and torpedoes.

Responsible for all quality activities with specific customers, programs and contracts.

Reviewed and approved all operator build instructions & quality checklists related to each part number.

Completed containment actions, root cause analysis, developed corrective actions, composed and submitted

corrective action reports and answered follow-up questions from customers.

Reviewed customer purchase orders for all quality requirements to assure full compliance.

Designed, developed and implemented gauging as needed for each specific part number.

Developed and implemented process audits to assure production compliance with work instructions.

Worked with customer and government source inspectors on First Articles within the AS-9100 system.

Analyzed and reported reject data, and developed improvement plans for each part & program.

Developed and implemented error-proofing where applicable to achieve 100% conformance.

Worked with suppliers to flow down quality requirements and issue/approve their corrective actions.

Conducted internal quality audits in ISO-9001 & AS-9100 registered quality system.

Achieved Supplier of the Year award for a major Raytheon defense division.

JOSEPH H. LUKAS PAGE 2

MOLEX INC., Maumelle, AR 2006 – 2009

Quality Engineer, Connector Products Division (Position eliminated)

Products: Computer circuit board connectors for use in high-end workstations and servers.

Responsible for all Quality activities in the Final Assembly and Test of assigned connector products. Served as

primary contact for customer complaints. Over 75% of customers were located in Asia.

Completed containment actions, root cause analysis, developed corrective actions, composed and submitted 8D

reports and answered follow-up questions.

Reduced backlog of open customer complaints and improved response time.

Met or exceeded department complaint goals for 10 of 12 months in fiscal 2008, including two 60 day periods of

zero new or open customer complaints.

Analyzed and reported reject data and developed improvement plans.

Reduced scrap an average of 40% on key processes, such as the new I-Trac connector.

Developed and revised all related Quality documents and instructions.

Conducted ISO-9001 and TS-16949 internal quality system audits.

Participated in Advanced Quality Planning (APQP) for new products and equipment.

Active team member on multiple successful Green & Black Belt Six Sigma projects.

MAYTAG, Searcy, AR 2003 – 2006

Staff Quality Engineer, Laundry Products Division of Whirlpool (Plant closure)

Products: Maytag, Amana, and Crosley Electric, Gas & Export Clothes Dryers for household use.

Responsible for all Quality activities in the stamping, welding and painting areas. Supervised 3 hourly Quality

Technicians who programmed & ran CMMs and did Gauge Calibration.

Co-leader on the Dryer Improvement Team that reduced the National Service Call Rate by 15% in 8 months.

Purchased 2 new automatic CMMs that improved measuring capabilities over manual CMM.

Lead capability improvement effort on internally fabricated parts. Actions increased critical characteristics that

were capable from 63% to 88% within 18 months.

Started automatic data collection on important characteristics on all fabricated parts.

Used Minitab statistical software for capability studies and Gauge R&Rs. Conducted over 60 Gauge R&Rs.

Organized and submitted PPAPs for new or changed internal parts and production tooling.

Participated in various Lean, Six Sigma, & Kaizen Events to improve quality, cost and delivery.

Conducted ISO-9001 internal quality system audits.

WHITE-RODGERS Division of Emerson Electric, Harrison, AR 2001 – 2003

Senior Quality Engineer (Plant closure)

Products: Natural gas valves, solenoids, electric coils, air cleaners and injected plastic parts .

Responsible for Supplier Quality, ISO-9001 Internal Audits, Statistical Process Control, and Returned Goods.

Headed ISO-9001 internal auditing program, including scheduling and lead auditor functions.

Successfully upgraded ISO-9001 registration from the 1994 to the 2000 standard.

Managed Receiving Inspection and purchased Material Review Board activities, including issuing, tracking and

approving supplier corrective actions.

Developed detailed work instructions for assembly members.

Doubled the Non Value Added savings goal on Six Sigma Greenbelt project.

DELTA USA CORP., Aurora, MO 1997 – 2000

Quality Engineer (Plant closure)

Products: Assembly of automotive seating for OEM, Commercial Bus, and Aftermarket.

Staff-level position reporting directly to plant manager. Responsible for all quality-related activities in a QS-9000

facility, including department budgeting. Customer and supplier quality contact. Supervised one salaried Quality

Technician.

Achieved QS-9000 registration on first attempt within 10 months of starting.

Reduced PPM customer returns by 60% within 3 years.

Reduced customer complaints by 80% and improved the response time.

Developed Flow Diagrams, FMEAs and Control Plans.

JOSEPH H. LUKAS PAGE 3

BECTON-DICKINSON, Columbus, NE 1995 – 1997

Quality Engineer

Products: Glass syringes of various sizes for the world-wide pharmaceutical industry.

Plant had begun a major renovation and equipment expansion, including upgrades to the Class 100 Cleanroom.

Supervised one salaried Quality Analyst. Plant is ISO-9001 & CE registered.

Created test protocols and conducted process validations on new and rebuilt processing equipment.

Developed new camera inspection system for 100% checks of formed glass syringe tips which dramatically

improved operator information and quality.

Investigated and responded to field complaints from both US and European customers.

Managed gauge selection and calibration activities.

GEORGE FISCHER SLOANE INC., Little Rock, AR 1992 – 1995

Quality Engineer

Products: Plastic injection molded plumbing fittings, valves and extruded pipe.

This was a new plant start-up, which involved integrating a total of four plants into one facility. Reported to Corporate

Quality Manager. Supervised two salaried and two hourly positions. Also supervised plastic regrinding operation.

Developed comprehensive training materials for new employees and standardized inspection methods.

Purchased new product testing equipment and gauging, plus implemented a gauge control system.

Managed the regrind operation and reduced inventory of material to be reground.

EMERSON ELECTRIC, Rogers, AR 1988 – 1992

Assistant Quality Manager (Plant now closed)

Products: Fractional horsepower electric motors for specialty customers.

Directed two Quality Engineers and four Quality Auditors covering receiving inspection, final assembly and final audit

for five separate product lines. Served as primary customer contact for Quality issues and developed SPC program.

Spearheaded PPM reduction efforts for Focus Customers, which lead to many supplier quality awards along with

increased sales and market share.

Trained over 200 hourly associates in basic SPC charting and data pattern analysis.

Implemented SPC charting in various production areas including Final Assembly and Shaft Grinding.

ITT AUTOMOTIVE, Searcy, AR & Archbold, OH 1984 – 1988

Quality Engineer (Plant now closed)

Products: Small diameter steel tubing used in emission, fuel and brake lines for automotive customers.

Promoted from SPC Coordinator. Duties included implementation and maintenance of Statistical Process Control

program leading to reduced customer complaints and scrap. Supervised one SPC Technician.

Took a leadership role in achieving supplier awards from Ford, GM and Chrysler, which improved our ability to

bid on new contracts. Assembled evidence books to show compliance for multiple customer audits.

Worked with ITT Statistical Programs Group using Gauge R&R, Designed Experiments and other statistical

techniques to improve the effectiveness of the Statistical Process Control program.

Assisted two other plants in the automotive tubing division to improve their SPC programs.

EDUCATION and TRAINING

BS, Industrial Management, University of Arkansas, Fayetteville, AR

ISO-9001 / TS-16949 Internal Process Auditing seminar, 2007

Maytag LeanSigma Black Belt training, 2006

Emerson Six Sigma Green Belt training & certification, 2002

ASQ Certified Quality Engineer, 1992 – 1995

ASQ Quality Engineer in Training, 1986 – 1992

Planning with MPACT - software training, 3 day class – 1999

Design of Experiments 3 hour college class, Grade = A – 1996

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