Manager Quality Assurance
Resume:
Gregory R. Dail
**** ****** ******* * Adrian, MI * 49221 * Phone: 517-***-****, Cell
* E-mail: *******@*****.***
Candidate Summary
Hands on leadership! Certified Six Sigma Black Belt and TS 16949/ ISO
9001, Lead Auditor with 10 years of OEM (Ford) automotive quality
experience. I am passionate about driving quality performance to meet
customer specifications. Walking the process with subject matter experts
has been my most effective team building tool. My Six Sigma teams have
developed consistent quality and lean production processes. In addition,
my teams have utilized Kaizen events, 5S, TPM and Develop Standard Work
documents to drive continuous improvement projects.
Education
Certified Six Sigma Black Belt, Six Sigma Academy, November 2000
Certified Lead Auditor ISO9001:2000 and ISO14001, IACTA, July 2000
Certified Lead Auditor TS16949
BA in Marketing, Cedarville College, Cedarville, Ohio, June 1992
Experience
Continuous Improvement Manager - May to November 2014
Martinrea Int. in Jonesville & North Adams MI
Primary Processes: High volume stamping, robotic welding and assembly
Main Customers: Ford, GM, Chrysler, Honda, TRW
. Report to Director of Operations
. Establish plant departmental KPI's with management team
. Drive improvements in all functional departments (safety. quality
productivity)
. Improve plant financial performance
. Assess systemic failures and apply countermeasures with management
team
. Develop teamwork and communication initiatives with all department
managers
. Direct continuous improvement strategy and drive change throughout the
plant
Quality Manager / Six Sigma Black Belt - August 2013 to May 2014
Hi-Lex Controls in Hudson, Michigan
Primary Processes: High volume assembly, plastic injection molding,
progressive stamping and roll forming, and welding
Main Customers: Ford, Chrysler, GM
. Report to President of HCI
. Managed quality department of 16 staff members
. Improved QMS to meet and exceed key monthly objectives (Customer PPM
from 13 to 2.5,Internal PPM from 1500 to 750, Scrap 0.3%, )
. Managed new part launch activity with cross functional team for OEM's
. Lead continuous improvement teams ( Six Sigma, Kaizen, RPN reduction,
Quality Circles,)
. Maintained TS16949 QMS (weekly MR meetings, improved LPA system)
Quality Manager/ Six Sigma Black Belt - January 2011 to August 2013
Metaldyne Two plant locations in Litchfield, Michigan
Primary Processes: Machining, high volume assembly, bonding rubber to
metal
Main Customers: Ford, Chrysler, Nissan, Cummins, Military
. Managed quality department of 12 staff members
. Improved QMS to meet and exceed key monthly objectives (Customer PPM
from 34 to 11, Scrap % to sales from 6% to 2%, QPPLH)
. Managed new part launch activity with cross functional team for OEM's
. Lead continuous improvement teams ( Six Sigma, Kaizen, RPN reduction,
MOS,)
. Launched new training initiative (See one, Do one, Teach one) plant
wide to certify operators and improve competency of operators
. Eliminated self imposed GP12 on 70% of all finished good within 10
months
. Maintained TS16949 QMS (weekly MR meetings, improved LPA system,
improved gauge system integrity, streamlined document control process
flow in agile system)
. Managed supplier quality and supplier approval system (85 core
supplier base)
Phillips & Johnston Inc. Three plant locations (Michigan, Illinois)
Quality Assurance Manager / Six Sigma Black Belt- July 2008 to January 2011
. Report to Vice President of Operations
. Develop and train floor operators in all three plant locations
. Work with operations to develop monthly targets and objectives for
each plant
. Manage and improve Quality Management System (QMS) with hands on
floor work
. Drive continuous improvement programs (Six Sigma, Kaizen Events, 5S)
. Work with sales force to resolve customer issues and provide technical
assistance on new product development
. Assist with quoting new projects with account managers
. Review profitability performance of existing business with account
managers to identify continuous improvement opportunities
. Report on status of QMS and continuous improvement projects each week
to all employees and executive staff.
Quality Assurance / Continuous Improvement Contractor - Adrian, Michigan
Self Employed Quality Assurance / Continuous Improvement Contractor:
December 2003 to June 2008
Black Belt for Tier 1 automotive supplier:
. Develop continuous improvement Black Belt projects
. Train quality engineers to use continuous improvement tools
. Implement TPS programs
Contract work for 3 franchised businesses:
. Prepared small businesses for annual third party quality assurance
review
. Created new quality system
Contract work for a large cabinet assembly plant:
. Developed supplier quality and internal quality performance
. Reduced direct labor costs and non-conforming product by using Six
Sigma methodology
. Level load work station to increase productivity
. Conducted Kaizen events for mid size assembly plant
. Lead 5S audit teams
. Created Standard Work documents and trained production supervisors on
Standard Work Program
Ford Motor Company (FCSD) - New York PDC
Quality Manager & Six Sigma Black Belt, March 2000 to December 2003
Production Supervisor, July 1999 to March 2000
Supplier Development & Buyer, June 1998 to July 1999
. Reported to Plant Manager and Corporate Quality Director
. Evaluated of Tier 1 suppliers against Q1 performance objectives
. Conducted on site supplier visits to confirm corrective actions for Q1
reinstatement
. Coordinated production purchasing with new supplier sourcing
. Communicated production changes to suppliers and discuss impact issues
. Managed quality department staff (5 to 8 direct reports, 35 indirect
reports) to maintain current quality system and work with production
teams on Six Sigma Green Belt projects
. Established quality programs both corporate and plant level objectives
. Ensured quality program was compliant with ISO9001:2000 and ISO14001
standards daily
. Reported to Project Champion and Master Black Belt on project status
. Assisted Plant Manager and Operations Manager on best potential
project selection
. Conducted training sessions for over 75 Green Belts and mentored
ongoing assigned projects
. Required monthly Green Belt project status reports, offered additional
training and leadership for project success
. Completed 3 Black Belt projects per year that saved over $250,000 hard
savings per project
. Conducted conference calls to mentor new Black Belts in North America
for best practice replication
GM Powertrain - Lansing, MI
Traffic Manager, January 1996 to June 1998
. Maintained inbound and outbound quality objectives
. Worked on cross functional team to improve machining operation issues
to keep up with assembly line demand
. Conducted on site visits to foundry plant to address delivery and
quality issues with cross functional team members
. Reduced transportation costs year over year (YOY) 5%
. Monitored daily dock operations with dock supervisors
. Reported to the Plant Manager daily on delivery metrics
. Worked daily with plant personal on changing build requirements and
adjust transportation routes if needed
. Assisted the quality assurance team with containment of non compliant
stock to be reworked or scraped by vendors
. Worked with Packaging Engineers with root cause analysis of damage
stock being received from vendors
. Conducted performance reviews of carriers
. Negotiated carrier rates on current and future lanes
Personal Skills:
. Certified Six Sigma Black Belt
. Certified Lead Auditor ISO9001:2000, ISO14001
. TS16949 (in progress)
. Quality Tools: 8D, PPAP, PFMEA, DOE, Hypothesis Testing, MSA, Gage R&R,
APQP, SPC, DMAIC, DFSS
. Lean Production Skills: Kaizen events, Total Productive Maintenance
(TPM), Toyota Production System (TPS), Standard Work, 5S, One piece flow,
synchronous material flow, JIT, DFSS
. Computer Programs: Word, Excel, Minitab, Power point, Outlook
. Train the Trainer
. Facilitator training
. Certified salaried personnel assessor
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