Quality Assurance Manager
Resume:
Resume: Barbara M. McCullough
Raleigh, NC 27614
********@***.***
OBJECTIVE:
Seeking a Senior Managment position where my experience directing Lean Manufacturing, Quality Assurance, Project
management, Operations Management, Data Analytics and Continuous improvements can achieve the best value-
added solutions for the organization.
SUMMARY OF QUALIFICATIONS
Senior Manager responsible for directing the leadership and optimization of the manufacturing processes by utilizing
Lean, Six Sigma, and Deming’s 14 points of Quality Management and data analytics. I am responsible for directing
and initiating company goals and objectives, and developing better methods to improve bottom-line profitability
across (2) facilities. Work with management to develop strategies by planning, and providing problem resolution to
support the manufacturing process. Responsible for all Supplier development by performing, leading, directing
external audits of their Quality Systems per ISO 9000 -2008 requirements. Great communicator with strong technical
capability along with superior management skills who can convey the companies needs with clarity and enthusiasm
through superior project management, and organizational skills.
Solid understanding of any guidelines/processes associated with ISO: 9001: 2008, ISO/TS 16949:2008, AS9100 compliance,
ITAR, RoHOS, Mil STD, PPAP, APQP standards, DFMEA, PFMEA, DMAIC,CAPA, Business Analytics, Cost Analysis .
Computer skills include: MS Word, Excel, Access-guru, Project Seeker, Power Point, SQL, and Internet Research.
PROFESSIONAL EXPERIENCE
Senior Quality Assurance Manager (Current) 2003-Current Position
Hi Tech Fabrication, Raleigh, NC- Manufacture of Close Tolerance Sheet Metal Fabrication/ Box Build Mechanical
Assemblies/Electro-Mechanical Assemblies
o Directed the development and implementation of all training facilitation of the entire Quality Management System
program plant wide for 2 facilities. These responsibilities include development of inspection criteria,
workmanship training programs, internal leadership quality development, CAPA training, DMAIC, PFMEA,
MSA, and applicable PPAP requirements. This would include development of manuals and training material.
o Responsible for the facilitation and directing of the capital budget expenses for the quality department.
o Directed the leadership and training necessary for all ISO Quality Management System requirements.
o Directed the planning, design, and implementation of a company- wide on-line database utilizing Microsoft
Access and SQL across (2) facilities. This db is used to track company data for business strategies, customer
issues, supplier issues, cost accounting vs. estimated timing, and calibration; along with internal product
conditions to develop better methods of product delivery. This would include documenting and performing all
applicable plant wide LEAN/Workmanship training, and applicable db training.
• Perform data analysis of the given data and draw accurate inferences, in accordance with the objectives of the analysis
• Gather data required to conduct analysis from several sources, compile it together in prescribed format and create
reports for management to use when reviewing contract negotiations, and business strategies.
• Evaluate the given problem, situation and crisis based on empirical data; investigate for solutions using data analysis
• Determine the methodologies and procedures for carrying out effective data analysis. Provide training to staff members
on the new systems implemented
o Directed the development of an online Quality Analysis db for management to utilize for NPI (New Product
Introduction) product performance evaluation and cost analysis.
o Work closely with product and project managers on the implementation of new projects and infrastructures
including operational readiness, change preparation, change execution, and post-change QA validation.
o Experience and proven competence in managing delivery of multiple projects simultaneously through full data
management analysis.
Resume: Barbara M. McCullough
1917 Falls Farm Crossing
Raleigh, NC 27614
********@***.***
o Maintains product quality by enforcing quality assurance policies and procedures and government requirements;
collaborating with other members of management to develop new product and engineering designs and
manufacturing and training methods.
o Initiated, developed and managed the creation of a NPI process plant wide by utilizing APQP processes.
(PFMEA/CONTROL PLAN/Technical Process Review) This process is administered for all Prototypes, FAI, and
PPAP submission jobs.
o Developed and planned a highly successful Lean Manufacturing program within the facility. This program
required me to be a director, facilitator, trainer, great listener, and excellent communicator to the various
departments.
o Kaizen events were generated that created a cost savings of over 25K within the first 2 months.
o Leveraged existing plant floor space and equipment through Lean initiatives allowing a 50% increase in actual
sales by increasing capacities, in addition to reclaiming 35% of floor space in building 1 for new production
cells.
o Cultivated and championed a continuous improvement team environment throughout the entire hourly
workforce in (2) separate plants.
o Improved customer delivery performance from 70% to 96% while reducing lead times.
o Reduced scrap and waste by 26% through a 5-step problem solving process focused on the key variables
identified by a Pareto analysis of root causes.
o Developed a Supplier program within the organization to monitor performance levels.
o Define quality expectations to suppliers through the usage of scorecards and supplier non-conformance data,
communicate w/ the suppliers, and facilitate supplier improvements through Lean initiatives.
o Developed a highly functioning Supplier Quality System program that would incorporate supplier score
cards, audits, and training programs.
o Building 2 Initiative: Developed and managed the creation and implementation of an Electro-Mechanical
Assembly Department within the company at its building 2 location utilizing LEAN concepts. This additional
department transformation
o Created a cellular flow line utilizing JIT and pull processes.
o Created an ESD area with appropriate testing areas as required per ANSI standards
o Lead manufacturing team in equipment layout, capacity study, tooling development and overall
teamwork.
o The department was certified ESD as of April 2006, and allowed the company to experience an instant
growth within the first year. These additional manufacturing capabilities were above, and beyond the
sheet metal fabrication business.
o Developed and planned training for MSA (Measurement System Analysis) plant wide.
o Provide organizational and subject matter expert support for company acquisitions of new or existing
products, processes, techniques, procedures or facilities/equipment in regards to ensuring compliance with
applicable quality and regulatory criteria.
Consultant/Business Analyst October 2002- November 2003
Qualex Photo KRE Repair, Durham, NC- Re-Manufacture of Photo Processing Equipment
o Worked closely with cross-functional planning teams to develop content and goals for the current
business issues pertaining to machine quality and data challenges of Qualex. KRE department.
o Identified the specific strengths and weaknesses of the repair side of the machines and made
suggestions in specific areas of improvement utilizing analytical analysis of data.
o Developed, planned, and implemented a Repair Cost analysis program utilizing Microsoft Access
database. The departments would utilize these reports generated from the DB, and analyze the repair side of
the operations while determining if changes would be needed.
o Assisted with the development of a Standard cost model for each product that was remanufactured
within the Qualex /KRE repair organization. Reviewed any applicable data to determine trends and create
recommendation for Qualex /KRE repair center that would support annual cost savings.
o Worked with the team to develop functional specifications based on the gathered repair data and
system design specifications for Qualex KRE ensuring that the appropriate issues were identified, tracked,
reported on and resolved in a timely manner.
Resume: Barbara M. McCullough
1917 Falls Farm Crossing
Raleigh, NC 27614
********@***.***
o Assisted with the development of a quality program within the Qualex organization. This program
involved developing an ISO program throughout the organization.
Manager, Quality Assurance/Closing General Manager-
March 2001-June 2002
US Assemblies, Raleigh, NC- Manufacture of Assembled printed circuit boards and Contract Manufacturing (Facility
Closed Permanently)
o Responsible for the further development and coordination of all ISO 9002 Company Quality System
functions.
o Responsible for managing and training of all Quality Assurance, In-Circuit-Functional Test, SMT Testing. (35
Engineering/Quality personnel)
o Responsible for the production process, drawing up a production schedule according to sales requirements.
Making sure that products are produced on time and are of good quality, and that the production was cost
effective.
o Worked with Engineering to determine the manufacturing capabilities and the time scale for the job. Assisted
w/ developing and improving TAKT time. This review also incorporated the estimated cost vs. actual and
setting the standards accordingly.
o Worked with the Facilities and maintenance team for the selection and qualification of equipment.
o Work with managers to implement the company's policies and goals; and ensure that health and safety
guidelines are followed;
o Supervise and motivating a team of workers, reviewing their performance, and identify any training as
needed.
o Project Manager responsible for the transition of company assets to corporate headquarters. Also, responsible
for the transfer of customer product to other facilities. Handled all employee termination requirements
according to the company closure policies.
o Supervised remaining Managers/Employees until customer needs were completed and permanent closure of
the facility.
Manager, Quality Audit February 1997- February 2001
DT Magnetics, Knightdale, NC - Designed, develops, manufactures and markets complex Custom and Standard,
Power and Signal Magnetics Manufacture of Transformers for the Telecommunication Industry
o Developed all required ISO Quality Audit Programs within the DT Magnetic Companies which included,
South Dakota, Dover, NH., Raleigh, NC., and the Dominican Republic.
o Developed a Supplier Certification Program for the company’s corporate purchasing program that would
create annual cost savings of over 100K.
Evaluating the suppliers base through-out the DT Magnetics corporations
Evaluate the capacities and past performance through the use of new developed Vendor KPI.
Resume: Barbara M. McCullough
1917 Falls Farm Crossing
Raleigh, NC 27614
********@***.***
Work with the Purchasing department to determine expectations, and to develop key subcontractors
quality requirements.
Identify the bottleneck suppliers and develop contingency plans for delivery or quality issues.
Develop and implement overall launch plan to ensure proper delivery timing of supplier Product
Verification (PV) and First Article Inspections (FAI) aim to achieve customer requirements.
Develop an audit plan to assure Supplier product conformity can be maintained.
o Responsible for the implementation of an on-line Document Control System via Intranet capabilities.
o Evaluated for performance operations any software applications that would be utilized by the Manufacturing
departments.
o Responsible for developing and acquiring certification of ISO 9000 quality system throughout the
organization, and its affiliate companies.
Lead, Quality Assurance November 1989- February 1997
Sovereign Circuits, North Jackson, OH- Manufacture of Raw Printed Circuit boards for the Telecommunication,
Automotive Industry and Private Government Agencies.
o Thorough understanding of the PCB creation with experience with double sided to 20 layers, Lexan,
Polyimide, Flex rigid boards.
o Responsible for the assisting and coordination of all ISO-9002 / MIL-STD-55110E Standard Quality System
requirements.
o Assisted with all Government self-destruction testing requirements per MIL-STD-55110E
o Responsible for the Supervision and Training of all Quality Assurance Personnel
o Ran the electrical testing equipment as well as performing the essential diagnostics. Ex. (bed of
nails/clamshell testing/flying probe testing/net list testing.)
o Responsible for AOI (Automated Optical Inspection) inspection of inner layer of the PCB’s and any repairs
needed.
o Conducted Quality System/ Supplier Audits and Evaluation. Responsible for tracking delivery performance
and reject percentages for all outside vendors.
o Was a qualified source inspector for Harris Inc, Schlumberger, Houston Sigma, Scientific Atlanta
EDUCATION:
Pfeiffer University: Masters in Business Administration-2006
MT. Olive College: Bachelors of Science in Business Administration & Organizational Development
Green Belt Training: 2012 NCR Corporation
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