GERALD L. TUYO

***** ********** ****: 734-***-****

Westland, MI 48185 acp6z1@r.postjobfree.com

EXECUTIVE PROFILE

A visionary Quality Executive with extensive experience in the automotive industry with particular expertise in Quality Improvement. Track record of implementing initiatives that drive quality improvements, reduce costs and increase customer satisfaction. Six Sigma Black Belt with strong background in manufacturing operations and quality disciplines. Expert knowledge in Advanced Quality Planning, Problem Solving and Quality Systems. Proven ability to develop teams and improve processes to meet or exceed objectives. A strong, results-oriented leader with international exposure.

PROFESSIONAL EXPERIENCE

HBPO, Troy, MI 2011-2015

Tier 1 Automotive Front End Module Supplier with approximately 1.5 Billion in sales

Director of Quality (Americas)

Instituted a Supplier Quality Improvement initiative to identify top supplier improvement opportunities which ultimately resulted in a 90% reduction in supplier quality issues.

Conducted plant audits to identify internal improvement opportunities and then guided problem solving teams to effectively address those issues.

Initiated Layered Process Audits at the plant level and conducted Process Walks to improve process shortcomings and instill a greater level of quality discipline into manufacturing operations.

Implemented Poka Yoke Reviews to improve uptime metrics at all locations to ensure the safeguarding of manufacturing processes.

Trained, developed and managed Quality Engineers and Plant Quality Managers.

Served as the Environmental Representative for HBPO Americas, defined annual targets in coordination with Plant Management and achieved same.

Above actions culminated in warranty incidence reductions at all locations as well as 0 PPM with all customers in 2013 and 1 PPM in 2014. For this performance our company received the Supplier Excellence Award from our largest customer.

Magna Corporation, Highland, MI 2010-2011

Interim Plant level assignment at this Tier 1 Automotive Supplier (Seating Division).

Supplier Quality – Established Supplier Quality Performance metrics and worked with supply base to improve their quality performance. This included intervention and problem solving guidance, especially for worst suppliers/issues. Made an 80% improvement in Supplier Quality Performance over the year and assessed financial penalties for approximately 1 Million dollars.

FCI CORPORATION, Novi, MI 2005-2010

Tier 2 Automotive Supplier of connectors and connector systems with 1.5 Billion in Sales.

Director of Quality & Customer Satisfaction – Americas

Led all phases of Quality for the Americas organization. Responsible for plant Quality Improvement Initiatives, APQP, Six Sigma, Supplier Quality, PPAP and Customer Satisfaction.

Championed Disciplined Problem Solving training for key regional staff and plant personnel and then implemented concentrated Quality Improvement at all locations that resulted in a 98% improvement in customer quality metrics. Received the Annual FCI “Leadership Award” for this achievement.

Provided management oversight to Six Sigma cost saving project teams.

Introduced PPAP measurement and appropriate follow-up at all plant locations resulting in a 90% launch performance improvement.

Managed all phases of quality related to the closure of Americas facilities and successful transfer of product to Europe.

LEAR CORPORATION, Southfield, MI 1992-2004

(Acquired UTA in 1999). Tier 1 automotive supplier with $15B in sales.

Corporate Quality Director 2001-2004

Responsible for the development and implementation of a quality tracking system which included the supervision of a staff of six. Also led the company-wide quality training program.

Championed the development and deployment of a benchmark, global, web-based Quality Tracking System for 43 customers and 250 manufacturing facilities worldwide.

This system provided real-time quality metrics, historical performance information and the capability to drill through to specific problem resolution documentation.

Conceived strategic planning initiative for the “Quality First” program that resulted in a 50% quality improvement over 18 months and a savings of $25M.

Led Black Belt certification project that achieved a 90% improvement in the accuracy of quality data for 99 plants in the US and Canada.

Developed and delivered a quality training program for 7000 key employees worldwide that resulted in improved quality processes and systems.

Director of Quality, DaimlerChrysler Division 2000-2001

Provided quality leadership to 15 Platform Teams and three product divisions encompassing 66 manufacturing facilities. The DaimlerChrysler division had $1.6B in sales.

Initiated quality systems improvements at plants and on platform teams that resulted in a 23% quality improvement over an eight-month period.

Exceeded DaimlerChrysler Warranty Targets, resulting in a score credit of $5.2M.

Established and led work teams in the development of new division and plant level procedures and quality metrics.

Trained & developed Division Quality Team that continued to improve quality performance.

Senior Quality Manager GM Team (UTA / Lear) 1999-2000

Managed quality for the GM Division Customer Team and six manufacturing plants.

Led the quality turnaround at two facilities in Mexico, resulting in a 99% reduction of PPMs in a three-month period. This quality improvement initiative resulted in continuation of the business and restored credibility with customers.

Trained and developed the Division Quality Team sustaining the quality improvement gains.

Initiated GM Team Advanced Product Quality Planning & Continuous improvement processes resulting in high customer satisfaction with prototype builds.

Manager of Quality and Continuous Improvement (UTA) 1997-1999

Formed core competency teams to define company-wide program management processes.

Led four core competency teams that defined the company Program Management Process (PMP) for improving quality and reliability that became the industry state of the art model.

Provided leadership to seven Corporate Customer Team Quality Managers.

Expanded the implementation of a problem resolution process / system for 35 facilities throughout the Americas.

Quality Supervisor, Wiring Systems (UTA) 1996-1997

Trained and supervised 16 Quality Resident Engineers for multiple customers and locations in the US and Canada.

Led the development and implementation of a world-class problem resolution system resulting in a 30% improvement in overall quality metrics (80% at one customer alone).

Led QS9000 audit teams in the successful preparation for company certification.

Training Supervisor, Wiring Systems (UTA) 1994-1996

Developed and delivered management and quality training (new supervisor, leadership, positive discipline, problem solving and statistical process control).

Identified company-wide training needs, developed and delivered appropriate courses that resulted in cost savings of $200,000 and improved training.

Developed training package in Problem Solving, trained several hundred employees worldwide.

Delivered Leadership training to company plant personnel.

Quality Engineer, Input Controls (UTA) 1992-1994

Liaison to 40 major Ford customer plants; led new product teams in Advanced Quality Planning

MR. FIX-IT, Flint, MI 1990-1992

Owner / Operator of a small home repair business

GENERAL MOTORS, Flint, MI 1979-1990

Supervisory Positions (maintenance, manufacturing and quality)

EDUCATION / TRAINING

BA, Psychology, St. Martins, Olympia, WA 1978

AA, Liberal Arts, University of Maryland, College Park, MD

Extensive training in management and quality related fields to include:

DFMEA, PFMEA, MSA, APQP, PPAP, Statistics/SPC QS9000, TS16949, Six Sigma, Lean Manufacturing, Communication, Effective Listening, Leadership and more…

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