Quality Assurance Manager

GERRY J. MANCUSO

910-***-**** ~ acfbos@r.postjobfree.com

SENIOR QUALITY PROFESSIONAL

Quality Assurance ~ Quality Control ~ Quality Data & Systems

Multi-Plant Quality Systems ~ Documentation & Information Services ~

Regulatory Compliance

Manufacturing Testing & Inspection ~ Supplier Quality ~ Manufacturing &

Supply Chain Management

BUSINESS AND OPERATIONS EXECUTIVE with progressive success in a diverse

range of manufacturing and research operations for industries including

nuclear energy, aerospace and commercial construction. Exceptional business

acumen with significant success driving productivity, efficiency, cost, and

process improvements in all phases of quality and manufacturing support

operations. Certified Quality Manager, Quality Auditor and Six Sigma Black

Belt with experience in multiple quality systems including MIL-Q-9858A,

ISO-9000, NQA-1, 10CFRPart50 & 10CFR70.

Solid record of achievement in quality management, quality systems, quality

engineering, and North American regulatory and industry compliance.

Consistently manage projects and programs in a cost-effective and

expeditious way. Successful leadership of engineering, supplier, contract,

and operations teams with significant contributions to corporate strategic

vision in fast-paced, technologically evolving environments. Master of

Business Administration and Bachelor of Science in Mechanical Engineering

with additional qualifications including:

.( Multi-Facility . Project Management . Statistical Process

Manufacturing Control (SPC)

. Government & DoD Contracts . Supplier & Regulatory . ISO 9000

Relationships

. Quality Industry & . Staff & Organizational . Six Sigma & Lean

Regulatory Awareness Development

Technical/Computer Skills Snapshot: InfinityQS SPC software and Minitab

Quality / Statistical software.

Microsoft Word, Excel, and Project.

Career Highlights

. NQA-1 Lead Auditor for both Internal and supplier audits, while mentoring

auditors to Leads

. Supported the GLE License Special Nuclear Material SNM-2019 approval from

the NRC.

. Drove implementation of real-time, multi-plant SPC tool for US

GreenFiber, LLC. Directed hardware/software installation, using InfinityQS

to realize end-of-line performance improvements in bag weights, product

density, and chemical usage through application of real-time metrics -

resulting in intra-plant competition.

. Redesigned end-of-line test equipment to become industry standard,

creating a new revenue stream for GreenFiber through sales of equipment to

industry competitors and third-party test companies.

. Accomplished a 48+% reduction supplier DPM, from 7,261 to 3,743 and

steady reductions in external/internal failure costs, from 1.16% to .87%

of standard cost, through initiation of a Six Sigma receiving inspection

and end-of-line auditing as Quality Manager at Schlage Lock Commercial

Division.

. Eliminated my job and 15 architectural company positions, as Engineering

Program Manager and architectural liaison for GE Nuclear, using a Pareto

analysis and implementation of document-driven, problem resolution

process.

Professional Experience

GE-Hitachi / Global Laser Enrichment, Wilmington, NC 2008-Present

$1.0B in sales for nuclear fuel, spare parts and field services for

existing Boiling Water Reactors in the US and world.

GLE Quality Assurance Manager

. Execute the Global Laser Enrichment (GLE) quality assurance program.

. Oversee the internal and supplier audit programs

. Managed and assured the Corrective Action Program including periodic

report and performing Root Cause Analysis (TapRoot)

. Integrate GLE processes and procedures with GEH and GNF-A for efficient

operations.

. Work closely with GLE Staff, to eliminate roadblocks and communication

barriers that may affect quality requirements

Achievements

. Supported SNM License 2019 approval from NRC 8-2012

. Maintained assigned GLE suppliers active on the Approved supplier list by

performance of Evaluations, Surveys and NQA-1 Audits,

. Upgraded the GLE Corrective Action Program to be consistent with the GEH

program

Quality Assurance Project Manager

. Sourcing Quality responsibilities for assigned procurement and supply of

services, materials and products related to the nuclear projects

. Work proactively with suppliers to define specific quality requirements,

including development of inspection verification, qualification and

statistical process control methods, in addition to tests and processes to

assure products and service meet all requirements (quality, regulatory)

. Work collaboratively with Sourcing team to develop strategic supplier

quality plan and implement

. Provide technical guidance to suppliers toward assuring product/process

compliance with engineering drawings and specification

. Implement changes to improve processes and product quality, optimize

production of quality at the source, and eliminate failures/losses. Write

and review technical quality documents, plans and procedures. Maintain

Quality Assurance Programs and Procedures to assure compliance with

regulatory requirements

Achievements

. NQA-1 Auditor 6-08

. Maintained assigned 60 suppliers active on the Approved supplier list by

performance of Evaluations, Surveys and NQA-1 Audits,

. Green Belt Project: Set up a Source Inspection tracking process 8-2009

which received a General Manager Award.

. Obtained Q Clearance 10-2009 for GLE project

. Presented training of QA flow down and general PO training to 60 supplier

11-2009

. Set up a NCR batch reporting for GEH/GNF/SCO suppliers reducing query

time and improving supplier communications

US GreenFiber, L.L.C., Charlotte, L.L.C. 2003 - 2007

$176M manufacturer of cellulose insulation serving the residential home

contractor, manufactured home, and retail super store markets in the U.S.

and Canada.

Quality Control Manager

Managed quality assurance program charting overall product quality and

regulatory compliance for 12 manufacturing facilities. Coordinated

activities of 1 direct report and staff of 9 to 13, controlling a $1.5

million budget. Hired to develop more robust corporate quality program and

drive product quality improvement. Facilitated the execution of education

and training initiatives through Quality Technicians and Plant Managers,

driving quality best practices throughout the culture.

Managed regulatory and industry compliance, as primary contact and policy

originator in partnership with regulatory agencies and third party

suppliers / consultants. Served as regulatory / industry compliance expert

for diverse government and industry agency regulations, standards, and

building codes including the Consumer Product Safety Commission (CPSC),

Federal Trade Commission (FTC), Underwriters Laboratories (UL), American

Society for Testing & Materials (ASTM) standards, Canadian Construction

Materials Centre (CCMC), and the International Code Council & Evaluation

Service, Inc. (ICC-ES).

. Controlled third party testing contracts, facilitated regulatory and

industry testing, and managed implementation of mandated or recommended

operations/facilities improvements - guaranteeing ongoing compliance and

realizing cost improvements in third-party contracts.

. Planned and coordinated site inspections of four plants and Canadian

product testing for the CCMC, managing results filing and contract

relationships. Generated $30K in annual savings through change in

inspection services provider, from UL to Intertek.

. Managed annual inspections of all 12 manufacturing facilities, and

compliance with FTC & CPSC requirements. Realized a consistent record of

compliance to demanding CPSC criteria, with minor issues swiftly

resolved. Coordinated UL inspection of 4 plants.

US GreenFiber, continued . . .

. Researched, championed, and instituted technology, mechanical design, Six

Sigma, and metrics solutions that resulted in consistent improvements in

product quality.

. Realized substantial savings and quality improvements through leadership

of Six Sigma initiatives. Used throughput analysis to identify and

resolve constraints - resulting in a 10%-15% reduction in process

variation - providing greater consumer assurance of the labeled R-Value.

. Slashed defects per million (DPM), from 13,000 to 6,000, through design

and application of DPM and internal failure cost of quality (COQ) metrics

at all plants.

. Represented corporation and industry in the creation or refinement of

standards affecting GreenFiber product programs or customer base.

Maintained awareness of industry standards and regulatory environment to

ensure proactive initiation of corporate programs or communications to

minimize business or compliance risk.

. Submitted letter to the FTC demonstrating future state in the creation of

cellulose coverage charts using the proposed (2004) revision of R-Value

regulation, enacted in 2005. Avoided potential regulatory constraint of

the cellulose insulation industry through advanced documentation charting

successful alternative settled density testing. Use of both progressive

density and progressive R-Value (using ASTM standards) resulted in a more

accurate insulation value for the consumer.

(http://www.ftc.gov/bcp/rulemaking/rvalue1/comments/040708greenfiber.pdf

)

. Regularly participated in the creation or revision of ASTM standards

affecting the cellulose and fiberglass insulation industry, including

leadership in adoption of the Standard Specification for Cellulosic Fiber

Loose-Fill Thermal Insulation (ASTM C739 Rev 05), for the creation of a

cover chart using progressive density.

. Annually provided objective evidence of state regulatory requirement

allowing labeling and participation in both the California and Minnesota

markets.

. Championed process, operations, and business improvements through a broad

corporate leadership perspective that expanded beyond the quality

function. Generated annual savings of $250,000 through a 33% reduction of

multi-labeled bag types. Realized improvement through implementation of a

universal labeling process.

. Optimized internal corporate quality structure and systems. Rewrote QA

program, using ISO9000 structure, in compliance with International Code

Council ICC AC-10 requirements. Key improvements include a quality manual

and inspection & test program, and document control, nonconformance, and

customer compliant systems. Received approval of the company quality

program by the ICC-ES, as documented by ESR-1996 and Canadian CCMC Type 1

and Type 2 certification.

. Designed and instituted a multi-plant, Web-based document control system

and database, enabling group distribution, the maintenance of historical

revisions, and the documentation of electronic signatures. System

integrated workflow and provided change history for efficient future

reference.

Schlage Lock Commercial Division (Ingersoll Rand), Security, Colorado

1998 - 2002

$230M (2002) international leader in the manufacture of commercial locks

primarily targeting the school/university, hotel, and commercial building

industries.

Quality Manager

Directed all aspects of the division's quality assurance program, in

compliance with ISO9000. Assumed P&L accountability of $1.8 million budget

and management of team of 21 engineers, technicians, inspectors, and

administrative support personnel. Directed quality systems, quality

databases, calibration, first articles, receiving inspection, stockroom

audits, and customer returns for Schlage Commercial and Falcon Lock at

three manufacturing sites in Colorado, California, and Mexico.

. Contributed to corporate strategic and organizational planning, as key

member of team charged with the transfer of Falcon Lock production from

Brea, California to Security, Colorado facility, after Falcon Lock

acquisition. Developed and administered divisional quality budget,

achieving consistent budget compliance while achieving operational

improvements.

. Drove continuous quality program / supplier quality program optimization

- and resulting productivity, profitability, and quality improvements -

through study, identification, and application of enhanced technology or

process solutions, including Six Sigma methodology.

. Championed and directed implementation of a multi-plant quality

information system, integrating 20+ drawing, document control, and

approved supplier databases - including robust first article/incoming

inspection system - that enabled standardization to one information and

one metric system throughout four facilities. Rolled out successful

system throughout the corporation.

. Enabled Pareto analysis of suppliers through design of a supplier defects

per million (DPM) reporting and rating system integrated into Web-based

supplier scorecard and defect-code-sorting application.

. Instituted multi-plant measurement in the Web-based corporate scorecard

of key Six Sigma indicators, including DPM / defects per million

opportunities (DPMO) and COQ.

. Achieved shared-use capabilities for commodity managers and technical

inspectors through the upgrade of a first article inspection system.

. Enhanced design deviation tracking through implementation of a document

control system with online electronic signature capability.

. Optimized and expanded the calibration system, from 500 to 2,500 gages,

increasing inspection capability to 1,100 lots per month.

Chem-Nuclear Systems, Inc., Harrisburgh, Pennsylvania 1992 - 1998

Contract operator of low-level radioactive waste disposal facility in

Barnwell, South Carolina.

Quality Assurance Manager

Progressed from project management role, to safety & security management

and internal auditing function, prior to assignment as Quality Assurance

Manager. Planned and managed implementation of the 10CFR71 quality

assurance program for various programs, including the UX-30 nuclear waste

container overpack fabrication project, as QA Manager.

Contributed to potential site location mapping and qualification for new

facility in Pennsylvania, during initial project management assignment,

from 1992 to 1996. Tasked with Safety / Security and Nuclear Regulatory

Commission (NRC) NQA-1 compliance management for Harrisburg facility, in

1996, prior to QA Manager promotion. Audited Chem-Nuclear internal

processes, suppliers and at multiple nuclear power plants, prior to

transport and disposal at Barnwell.

Developed and improved quality procedures and served as primary contact to

the NRC, as QA Manager. Oversaw the management of QA support activities,

including project management, vendor surveillance, and auditing. Trained

project teams in quality, safety, and security processes.

. Earned NQA-1 Auditor designation. Audited nuclear facilities, suppliers,

and internal systems, as corporate NQA-1 subject matter expert and

representative.

. Performed traceability design reviews of Dewatering process

documentation. Improved processing and mechanisms in the maintenance of

quality assurance records.

. Established a database to track contract deliverables for customer

review, minimizing audit risk.

General Electric Company (GE), Valley Forge, PA ~ San Jose, CA ~

Schenectady, NY 1978 - 1992

$163B multinational American technology and services conglomerate & the

world's second largest company.

Earned consistent promotions throughout a 14-year career with GE,

progressing from Associate Buyer to Product Assurance Project Manager,

within GE Nuclear Energy, Gas Turbine, and Astro Space Business Units.

Product Assurance Project Manager, GE Astro Space Division, Valley Forge,

Pennsylvania (1990-1992): Directed quality assurance and quality control

functions for two satellite programs, Second TDRS Ground Station and

MILSTAR attitude control panel assembly, in compliance with MIL-Q-9858A.

Reviewed subcontractor plans for quality contract compliance. Improved

productivity by 15% through creation of an engineering redline design

control system. Optimized traceability through establishment of an as-built

production system, later sold to customer.

Supervisor Quality Control Engineering (Elec), GE Astro Space Division,

Valley Forge, Pennsylvania (1985-1992): Directed up to 12 Quality Control

Engineers in component assembly and testing for major Air Force satellite

programs in compliance with MIL-Q-9858A. Products included digital and

power black boxes, printed wire boards, and ground stations. Environmental

testing included vibration, thermal, thermal/vacuum, and acoustic chamber

tests.

Improved procedures for Materials Review Board and nonconformance material

control through enhanced training. Received customer award through design

and implementation of a quality summary system. Acted as costing manager

for programs up to $1 million.

Program Manager - Engineering, GE Nuclear Energy, San Jose, California

(1984-1985): Managed field deviation feedback program for nuclear power

plant sites under construction. Provided training at construction sites and

upgraded operating procedures. Compiled design/data records of nuclear-

qualified hardware into a sales catalogue. Eliminated position through

implementation of a problem-resolution flow process between architect and

GE.

Panel Engineer, GE Nuclear Energy (1983-1984): Reviewed control room design

for nuclear power plants under construction. Developed site orientation

books for field engineering training at Nine Mile Point II & River Bend

power plants.

Vendor Quality Control Engineer, GE Nuclear Energy (1981-1983): Managed

vendor quality reviews in the production of precision mechanical parts for

radiation sensors. Reduced incoming defects from 11% to 5% through

development of workmanship standards. Qualified as lead NQA-1 Auditor.

Supervisor Process Control Engineering, GE Nuclear Energy (1980-1983):

Directed 30+ Electrical / Mechanical Inspectors involved in the examination

oncoming and in-process materials through all stages of the manufacturing

process. Hired, trained, and developed job specifications. Reduced open

inspection reports by 91% through implementation of a corrective action

tool.

Quality Assurance Specialist, GE Gas Turbine (1980): Administered a quality

feedback system fir six foreign manufacturing associates in the contract

production of flow parts for large gas turbines. Evaluated problem trends

and initiated corrective actions. Tracked cost of quality by manufacturing

associate.

Third Shift Production Foreman, GE Gas Turbine (1979-1980): Supervised

union employees in high precision grinding mill shop for the manufacture of

buckets and blades for gas turbines. Improved existing rework cycle.

Mechanical Products Schedule Coordinator, GE Nuclear Energy (1978-1979):

Tracked machined parts prior to assembly in major subassemblies used in

nuclear power plants.

Associate Buyer, GE Nuclear Energy (1978): Purchased small electrical

commodities. Disposed of $1.2 million inventory within 3 months.

Education ~ Certification

Master of Business Administration - General Business, PEPPERDINE

UNIVERSITY, Malibu, California

Bachelor of Science in Mechanical Engineering, RUTGERS COLLEGE OF

ENGINEERING, Piscataway, New Jersey

Certified Six Sigma Black Belt (CSSBB) - Current - Issued 2002 (#677)

Certified Quality Manager (CQM) - Current - Issued 2002 (#52455)

Certified Quality Auditor (CQA) - Current - Issued 1996 (#14579)

GE Six Sigma Green Belt- Current - Issued 2009

RESUME ADDENDUM - PROFESSIONAL DEVELOPMENT

Training:

US GreenFiber:

InfinityQS SPC Training, Bell Leadership, ASQ Strategic Quality Planning,

Negotiation Skills.

Schlage / Ingersoll-Rand:

Quality: Six Sigma, ASQ-CQM Refresher Course (Pareto charts, flow charts,

cause and affect tools, checklists, control charts, histograms, scatter

diagrams, activity network diagrams, affinity diagrams, interrelationships

digraphs, matrix diagrams, priorities matrices, process decision program

charts, and tree diagrams), Management by Fact.

Engineering: Geometric Dimensioning and Tolerance (GD&T).

Business: Quality of Leadership, Designing High-Performance Organizations,

Project Management, MS-Project.

Chem-Nuclear Systems:

Computers: Global Information Systems (ARC INFO).

Business: Communications, Leadership.

Environmental: OSHA Hazardous Materials (40 hours), CPR, Radworker II.

General Electric:

Leadership: Advance Manager Course (AMC) 6/2010

Manufacturing: Manufacturing Management Program (MMP), and Manufacturing

Studies.

Quality: NQA-1 Lead Auditor, KT, Root-Cause Analysis, QC Course, TQM, SPC,

WorkOut, TapRoot

INPO: New Nuclear Oversight Managers Seminar

Engineering: Verification, Design Files, Change Control,

Interchangeability

Professional Affiliations

American Society of Quality (ASQ) 1993 - Present

American Society of Mechanical Engineers (AMSE) 1978- Present

American Standard of Testing Materials (International) (ASTM) - 2003-2007

Active in Committees C16 Thermal Insulation and E05 Fire Testing

International Code Council (ICC) 2005-2007

Cellulose Insulation Manufacture's Association of Canada (CIMAC) - Board

Member 2006 through 2007

Presentations

Importance of Voltage to Calibrate the Electric Radiant Panel Test Chamber

(ERPTC)

21st International Conference on Thermal Insulation Greenbrier White

Sulphur, West Virginia, 2006.

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