Quality Manufacturing

Education

Bachelor of Engineering: Industrial, (Mechatronics). National

University of Ireland, Galway

ASQ certified CQA, CQE. Certified Lead Auditor ISO 9000 / TL 9000.

Auditor ISO 13485 / AS 9100

Professional Summary

Global quality management and manufacturing experience in electronic

devices, EMS (SMT and PTH), power supplies, molding, Ceramics vacuum

brazing, Metal forming / stamping and associated chemical processes.

Key Skills and Attributes

. Build and direct Quality organizations including quality engineers,

auditors, inspection, in managing hardware, software and supply chain

quality, and certifying quality management systems to ISO/TL/AS

standards.

. Ensure that manufacturing engineering, operations and design engineering

interact sufficiently throughout the product planning and design phases

to ensure a seamless hand-off during NPI and to final production.

. Drive the use of Quality tools; apply Lean, 5S, Auto-quality and CI

methods to improve quality.

. Develop and institutionalize best practice quality tools within

manufacturing and supplier quality, establish metrics goals and KPIs for

each and drive improvement plans.

. Takes a lead role in building a culture that reinforces compliance with

appropriate regulations, and guidelines.

. Champion APQP activities including developing DFMEA, PFMEAs, PPAP and

Control Plans for new product development / introduction.

. Bilingual (Spanish), US person, will relocate.

Accomplishments:

. Transformed manufacturing plants outgoing quality < 500 PPM, reduced RMAs

by 50% and COPQ by 60%.

. Won long term contract with best quality, product and reliability metrics

amongst competing companies, and successfully maintained scores after

manufacturing transfer to Asia.

Experience

Asteelflash, US East Division, Owego NY 1/2013 to 10/2013

Asteelflash is considered the world's best tier II, Electronics

Manufacturing Services (EMS) Provider, specializing in high tech, high mix,

low and high volumes of PCBs, PCBAs and complex Box-Builds with revenues of

over $850MM and employing over 5,000 personnel in 26 global locations.

QUALITY DIRECTOR

Lead and developed the quality engineering, inspection, supplier

monitoring, continuous improvement and quality systems in two manufacturing

locations.

. Improved the process KPIs in SMT, Auto-insert, soldering lines, test

and conformal coating with improved inspection methods, QRQC / 8D

problem solving tools. Reduced supplier component defects.

. Reduced RMA quantities with better escape prevention and improved turn

time with the QRQC activity

. Cut scrap/MRB/COPQ by 60% with a custom NCMR reporting and management

program.

. Raised to outstanding the supplier rating from key DoD customer with

better outgoing quality.

. Reinforced the calibration / internal auditing / Doc. Control

activities for AS9100 recertification audit.

. Aligned the quality engineering, inspection processes to Corporate

LEAN, AES and 5S programs.

. Developed quality engineering review process to assure NPI process

design compliance with customer and quality standards compliance and

that component AVL, anti-counterfeit, RoHS and other special

requirements are all reviewed in detail as part of the NPI process.

Management Consultant / Contract Assessor 2009 to 2012

. Conduct ISO 9000 / ISO 15189 assessments, implementations and training

including GAP analysis / Assessment visits, QA manual/SOP/standardized

work instructions preparation on behalf of IMSM, a sales/ marketing

company. Train internal auditors, plan audit schedules, oversee audits

and generate management reports to business owners.

. Implement computer networks for small business including medical offices

and laboratories. Source hardware and software solutions including

digital radiography, practice management systems and POS, billing

systems.

Tii Network Technologies, Inc., Copiague, NY 1984 to 2008

Leading designer and manufacturer of gas tube surge protectors, network

electronics, metal / plastic components for the global telecom market.

Additional solutions include IPTV distribution, VoIP, and DSL products.

DIRECTOR OF QUALITY 1993 to

2008

Promoted to leadership team charged with rebuilding the quality function of

the manufacturing plants in the US, Caribbean and Asia. Using the TL9001

and ISO guidelines, reengineered the manufacturing operations to win

critical customer contract. Co-ordinate manufacturing transfers to Asia

with responsibilities for QA and Test.

Achievements:

. Awarded 5 year Verizon contract through best scorecard results amongst

competing companies on quality / OTD, TL / ISO certifications, and

implementation of a customer focused quality management system.

. Participated on TII / Raychem steering team to design / produce new

produce hybrid surge protectors for AT&T. Introduced D.O.E., variable

sampling, machine visual inspection, GD&T, and Lean/Kaizen. Successfully

replaced a Japanese competitor's product at AT&T.

. Re-equipped obsolete reliability testers with NI Labview control software

saving $600k in replacement equipment costs. Incorporated Labview in new

production testers. Set up QA network and developed software to manage

CAPA, NCMR, Vendor Performance, and ISO Internal Audit planning and

reporting.

. Formed a corporate Continuous Improvement team comprising Marketing, R&D

and Operations to establish and manage process metrics in key processes

including NPI, Inventory, OTD, Quality, COPQ, Customer Satisfaction and

contractual TL 9001 metrics.

. Drove the Structured Problem Solving / PFMEA / 8D in manufacturing and

ensured that quality techniques and test/measuring equipment matched

state-of-the-art/technological advances.

. Introduced new measurement technologies: X-Ray florescence, CMM for mold

measurements in a TPM mold maintenance program, RF testing of coaxial

surge protector, OGP vision systems in automated measuring and NDT

testing of resistance welded gas-tube / connector assemblies.

. Authored ISO 9002 compliant QMS in two acquired companies, DITEL

producing fiber optic network products and in Crown Tool & Die, a metal

stamping/CNC facility producing parts for GE, Lutron and Hubbell.

SENIOR QUALITY MANAGER 1989 to

1993

Promoted to Sr. Quality Manager in charge of quality in four manufacturing

facilities. Trained, and realigned a 53 person quality organizations to

improve quality and reduce COPQ after a period of rapid growth/expansion.

Achievements:

. Led 6 Sigma improvement project in gas tube manufacturing to optimize

testing, tube assembly, vacuum brazing and air-gap manufacturing

resulting in higher first-pass yields and a 80% reduction in failure

costs.

. Developed a database module for the ERP system to capture all costs of

poor quality data including scrap, rework, test and retest costs. The

COPQ were reported, prioritized, assigned and monitored for reduction.

. Improved customer trended quality levels in all plants, winning awards

including Ameritech Supplier of the Year. The improved metal stamping

facility was approved by GE, Hubbell and Lutron for stamped parts.

. Converted test equipment from attribute to variable measuring, reducing

test cycles whilst generating statistical data for the improvement

projects. Drove SPC projects in vacuum furnace, injection molding and

metal stamping areas.

MANUFACTURING ENGINEERING MANAGER 1984 to

1987

Transferred products within the United States, Puerto Rico, Dominican

Republic and Haiti, supervising engineers and test technicians, preparing

facilities, providing personnel training in electronics manufacturing and

managing production and delivery of switching power supplies including

after sales service and field repairs.

Achievements:

. Transferred PC power supply operations to Puerto Rico and set up sub-

contract board assembly in Haiti. Managed production, eliminated order

backlogs, reduced labor costs by 25% and return rates by 50%.

. Improved documentation department by introducing IBM CAD and PCs.

Converted all drawings to CAD format. Introduced CAD to metal stamping

plant for progressive die design.

. Set up sub-contract facility in the Dominican Republic, manufacturing

circuit breakers / wiring devices for GE. Managed plant, recruited and

trained production, QA, engineering, materials and maintenance support

staff.

. Designed a sneak current, overvoltage surge arrestor for DOD RFQ and

setup manufacturing in Haiti.

Ericsson, Athlone, Ireland 1979 to 1984

SR. MANUFACTURING ENGINEER

Supervised Production engineering, Industrial engineering and maintenance,

ensuring product transfers from Sweden and Denmark to Ireland, including

layouts, training, equipment design and work standards determination.

Achievements:

. Increased PCB assembly line running rate efficiency by 15% by using auto-

insertion equipment and light guided assembly methods. Achieved lowest

cost amongst competing ERICSSON factories in PCB production. Provided

subcontract PCB assembly/test for customers including Apple, DEC Corp and

BOSE.

. Transferred telephone manufacturing from Denmark to Ericsson's Irish

plant. Directed team of engineers setting up PCB auto-insertion

equipment, automatic backplane wire wrapping, and coil winding.

. Introduced knowledge based repairing of electronic products using semi-

skilled operators instead of test technicians resulting in 25% lower

costs and higher throughput through board test and repair.

. Implemented Lean, Kanban system in telephone assembly, improving

productivity and eliminating staging.

. Created, trained and supervised maintenance group for UNIVERSAL auto

insertion equipment and Gardner Denver automatic wire wrap machines

achieving 95% uptime of production work centers.

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