Quality Manager

DREXEL MATTHEWS

**** ********* ***** ********, ** 47203

812-***-**** (primary) 812-***-**** (cell) **************@*****.***

Background:

Quality Engineer / Manager / Director, IT leader with experience in automotive, electronic, metals

for fortune 500 Companies. Process Optimization / Continuous Improvement / Lean Six Sigma /

APQP, FMEA – Supplier Quality / Quality Audit / Best Practices / Compliance Analysis / Risk

Management / Program Management / SOX / COSO / EMS / OHSAS / Team Leadership and

Customer Satisfaction Improvement. Japanese & Toyoto Production & Quality System, Financial

Analysis and Audit, IT Project and Program Management, Configuration Management, Industrial

metal coatings/paint. Aluminum/metals industry: Metallurgical R&D, heat treat, castings,

coatings, stamping/forming, failure analysis, Plastic molding and rubber processes, aluminum die

casting, tubing processes.

Quickly and accurately diagnosed and resolved quality and operational performance issues. Established

quality systems that maintained compliance with EMS, OHSAS, DOD, ISO, TS, EPA, FDA and other

international standards. Skilled in risk analysis through background in corporate finance.

Audited Quality (QMS), Environmental (EMS), Occupational Health and Safety (OHSAS), Health Care

(ISO 13485), aerospace and other standards. Served as ISO lead assessor auditing to I SO 9000, TS

16949, ISO 13485, QS 9000, ISO 14000, AS 9100, and OHSAS 18000 standards. Chaired AIAG e-APQP

committee that developed the new XML standard for electronic transfer of B2B supplier quality data.

Served on ANSI standards committees. 20+ Years of experience in Automotive Industry as a Tier 1

Supplier.

Skilled in FMEA, PPAP, Core Tools, supplier quality, customer satisfaction, process automation and IT

project leadership. Automated QMS using Lotus Notes/Domino, Oracle and other IT platforms and

networking. Led projects in Europe, Asia, North and South America, and Australia.

BS Engineering: Quality from Warren National University. Additional coursework in Math, Chemistry,

Metallurgy, Statistics, Finance and Electronic Engineering Technology. Certified in SAS, Lotus

Notes/Domino, Oracle Quality, Sun UNIX Server Administration and QSI/IBS software. B2B and B2C

project leadership.

SELECTED ACCOMPLISHMENTS

Cut costs and boosted IT productivity. Company needed 120+ leased servers and large amounts of

bandwidth to support IBM Domino for hosting businesses, and QSi System Compliance Management

Software to streamline QM systems, environmental and OH&S processes. Led Six Sigma project to

reduce IT budget expenses. Cut costs by $900K.

Enabled key supplier to meet increased product volume demands. New product development and

changes in US and European emission standards boosted need for components available from only one

vendor, who could not meet the new order schedules. Led Lean / Six Sigma project to increase

manufacturing volume at supplier’s sole plant. Improved cell efficiency. Reduced throughput time from

seven down to four days, increasing volume 50%. Cut manufacturing cos t and scrap, while earning

company exemption from 10% price increase from supplier.

Unified uncoordinated quality management system . 120 company facilities worldwide used different

quality management systems, making universal best practices implementations impossible. Established

uniform technical standards for gap analysis. Established QMS system within four months for eight sites

(well ahead of the 18-month deadline), meeting ISO 9000 and TS16949, and ultimately ISO 14000

(environmental) and OHSAS 18000 (safety) standards . Subsequently implemented at all 120 sites in 96

countries. Decreased cost of quality management system by $2M annually. Secured Aberdeen Group’s

Best in Class Award for QMS.

Automated labor, time and space-intensive production process. Manual production required

extensive drying rack space and up to 36 hours of drying time, created bottleneck and significant quality

problems. Led Mepco Lean project to automate and standardize the process. Reduced sealant scrap by

99%, lessened needed floor space from 400 sq. ft. to 30, cut staffing from 12 to three and slashed failur e

rate from 40,000 per million to just one ppm.

Revised energy utilization process to assure product supply despite limited energy resources.

Energy costs had risen 30% while energy supply had dropped by 40%, causing an unwanted reduction in

production hours and output. To avoid missing shipment commitments, redesigned recycling of available

volatiles back into the heating process. Cut need for limited availability gas fuel. Achieved $67K saving for

each eight hours of production time, while enabling National Aluminum to continue to produce needed

product volumes.

CAREER SUMMARY

Karatuck Consulting, 2012 to Current. Consulting in Quality Management Systems, Software, IT, Sales,

Manufacturing, and Diesel Fuel Systems. W orked with preparation for implementation of revisions to

ISO90001 and impact on TS16949, MSA, 6-sigma, FMEA and continuous improvements to improve

customer satisfaction and supplier improvement, increasing direct sales and imrovements to

business/quality management systems software. I was also involved in research projects for diesel fuel

systems and automotive steering systems.

Quality Manager, JTEKT (Tier I auto supplier), 2011 to 2012. Responsible for quality functions, supplier

management/SQA, process control, product and reliability t esting, and warranty management for this tier

one manufacturer of automotive steering systems for GM, Toyota, Honda, Nissan, Subaru and others.

Controlled $6M budget. JTEKT is Tier I auto supplier. W orked with die casting supplier to improve

equipment utilization and defect elimination.

Principal, Karatuck Consulting, 2009 to 2011. Consulted in quality management, calibration systems,

and standards compliance, software development and IT technical requirements,

Director / Manager of Corporate Quality Management Systems, Cummins Inc. 1997 to 2008.

(Cummins is a Tier I auto supplier.)

Developed and implemented Quality/EMS/OHSAS management and software systems. Implementation,

training, revision control, upgrade projects and off shore help desk & support. Member of corporate IT

architecture review board, Taught FMEA, APQP and core tools to JV partners, suppliers, and Cummins

employees worldwide including China, Russia, Europe, Japan, Brazil, Mexico, Canada and other

locations. Served as subject matter expert for AIAG on APQP, PPAP, FMEA, and other related items for

the AIAG e-APQP committee. Also, chaired this AIAG committee and received Outstanding Achievement

Award from AIAG /Automotive Industry for the work on the committee when standard was published.

Also authored the IT implementation and interface processes for the QC13 Standard.

Manager, Business Process Audit & Analysis, (Corporate Finance), Cummins, Inc. 1995 to 1997

Conducted business risk analysis and consolidated audits for fin ance, quality and safety. Developed

annual audit schedule, planned and led audits based upon risk analysis results worldwide. Created

automated risk software and taught auditing and software classes in addition to implementation of

periodic self-audits.

Rocky Mount Engine Plant: Business Unit Manager, Mid-Range Engine Group Fuel Systems, Cummins,

Inc. 11/1987-7/1995. (Cummins is a Tier I auto supplier.)

Managed the Mid-Range Fuel System group including Supplier Quality, Fuel System lab that set final

calibration of fuel systems for daily JIT production line set, Customer complaints, New Product

Introduction/APQP, reliability testing/teardown analysis, final audit of product, EPA/DOD requirements

compliance. ISO9001/TS16949 certifications, internal audit, supplier audits, SPC. Development and

implement automated quality system software for test/spc and Quality Systems. Taught FMEA to

suppliers, Cummins employees.

Prior:

Quality Senior Managing Engineer with Sumitomo Electric. Manager of Quality, Process, Manufacturing,

Specification Engineering and FMEA for Mepco Electra Division of North American Philips. Various

technical and sales positions with National Aluminum Division of National Steel. Technical activities

included but were not limited to metalurgical R&D, casting and rolling mill process improvements,

destructive and non-destructive testing, heat treatment research and development, failure analysis and

coatings control and development. Also worked with the die casting and extrusion customers on process

and product improvement.

Contact this candidate