Quality Manager

DOUG LEWANDOWSKI

**** ******** ***** ******, ********, OH 43560 419-***-**** *****@***.***

PROFESSIONAL CAREER EXPERIENCE

L&W Engineering, Plant 4

Blissfield, MI July 2014 - Present

TS 16949 Recertification Project Manager

Created recovery plan for TS 16949 recertification after company surrendered their registration during June 2014 audit.

Established QMS gaps, action plans and timing for 2014 recertification.

Training employees in work instructions and QMS processes, procedures and work instructions. Address associates in plant-wide meetings as necessary.

Successfully lead and passed Stage I audit. Lead stage II audit, resulting in 4 findings. On track for successful recertification by September 2015

The University of Toledo

Toledo,OH 2006 – Present

Engineering Instructor, part-time

University of Toledo College of Engineering, MIME department

Teach various classes including Facilities Layout Design & Planning, Statistical Design of Measurement Systems, Engineering Economics, Operations Research I & II, and Statistical Quality Control, and Design of Experiments.

Incorporate Excel spreadsheet applications of operations research methods including linear programming, plant layout, and statistical analysis into scheduling, assignment and other optimization applications.

Alex Products, Inc. Dec 2013 – Jun 2014

Ridgeville Corners, OH

Corporate Quality Manager: TS 16949 Audit preparation

Managed QMS for 3 facilities doing $80M in annual automotive sales

Successfully maintained TS 16949 quality system and passed audit for 3 locations.

Planned and assisted in successfully launching $20M Magna CD program

Planned and acquired quality equipment needed.

Identified and acquired TransFormation software to accelerate data entry and PPAP submission.

Strengthened CMM group to support new product launches.

Achieved 6 month external customer PPM of <10 PPM company-wide.

Drove quality improvement in weekly management reviews for Alex Products.

Dura Magnetics, Inc.

Sylvania,OH Aug 2012 – Dec 2013

Quality Leader: Projects include ISO 9000 Registration, Quality/Logistics Integration, Process Flow Definition

Led Dura’s ISO 9001:2008 registration effort to achieve registration in December 2013.

Streamlined and maintained day-to-day quality activities through re-layout of facility and application of one-piece flow methods.

Merged back-end operations (quality and logistics) in order to eliminate wasteful movement and non-value added activities.

Applied statistical sampling techniques to minimize overall cost of quality while improving ability to detect out-of-control conditions.

Created quality training plans for all team members.

ESW, Inc.

Crown Point,IN 2010 – 2012

Project manager: Projects including refining and steel manufacturing, ISO 9000 Accreditation

Developed procedures, work instructions, curricula and training manuals for clients to meet company training and regulatory requirements, such as ISO 9000, 16949, etc.

Developed customized Excel worksheets for real-time inventory control and optimal scheduling and loading of vehicles

Developed training plans for Supply Chain group for ISO 9000 compliance.

Trained employees in procedures to ensure proper understanding.

Learned and trained employees in use of company-developed software applications.

Middough Consulting, Inc.

Toledo,OH 2007–2010

Project Manager, Refining, Quality Inspections, Contractor Supervision

Engineering Projects, Inspections and Management Activities

Coordinated inspection activities as part of a $40M refinery upgrade program (“Naptha Sim”).

Coordinated union and non-union inspection, insulation, and scaffolding contractors as well as other specialty contractors to ensure that inspections were completed on-time and on-budget.

Managed non-conformance (NCR) resolution process from internal audits and follow through to completion utilizing Sunoco and subcontractors as needed.

Wrote and managed purchase/work orders and tracked to stay within $6.1M budget. Developed real-time tracking system to highlight overages.

Achieved 100% on-time inspection status for Sunoco's RBI inspection program (>2000 locations) without a recordable injury or OSHA violation.

OSHA, ISO and Safety Activities

Developed and presented daily safety meetings to maintain the inspection department's zero recordable incidents status.

Managed non-conformance (NCR) resolution process from internal audits and follow through to completion utilizing Sunoco and subcontractors as needed.

Developed and presented daily safety meetings to maintain the inspection department's zero recordable incidents status.

Toledo Metal Spinning

Toledo,OH 2002 –2006

Plant Manager

Managed plant doing $6M annual sales. Primary customers were equipment builders in a variety of industries (Injection molded machinery, food processing equipment, electrical power distribution, military).

Improved on-time delivery performance from ~80% to 96% through Theory-of-Constraints management methods.

Responsible for quality assurance and human resource functions. Maintained QC room’s equipment, ensured that MIL standards and ISO 9000 procedures were followed as customers required them.

Hired, trained, disciplined employees as necessary.

Implemented and strengthened lean manufacturing and quality practices in a job shop environment, including day-by-the-hour charts, quick die change, and kanban inventory management.

Led Toledo Metal Spinning to their first Gainsharing payout since program was initiated 2 years prior.

GT Technologies

Perrysburg, OH 2001 – 2002

Director of Quality

Resolved a major sub-supplier quality issue that could have interrupted one of GT's “Big 3” customers. As a result, implemented the sub-supplier's corrective actions across GT facilities.

Established common, standardized quality metrics for the division (6 plants in US and Canada).

Coordinated quality efforts at GT Technologies to support overall QS 9000 quality registration.

TG North American HQ

Troy, MI 2000 - 2001

Quality Manager

Set up North American quality reporting system to support TG North America manufacturing companies.

Coordinated quality efforts at TGNA (headquarters) to support overall QS 9000 quality registration.

Assisted operations as needed in quality training, consulting, and other related support.

Attended customer quality meetings to discuss issues requiring TG's action and resolution.

Eaton Corporation 1989–2000

Quality Manager

Eaton Innovation Center 1994–2000

(Responsible for Detroit and Milwaukee locations (~450 people total)

Led Detroit Center to achieve Eaton Quality Award in 1996.

Led Detroit Center to achieve Michigan Quality Award “Honor Roll” in 1995 and 1997.

Initiated implementation of ISO 9001 quality system in Detroit.

Established supplier audits for key suppliers.

Established internal audit system for management system review.

Established Corrective Action and Issue Resolution system to "close the loop" on all open corrective actions in the Center.

Established quality measures for the center (Cost of Poor Quality, timecard accuracy, project deliverables % complete, delinquent projects).

Managed EMC lab as a separate “profit center” with annual revenues of $1.3M+ and 15% annual growth.

Corporate Quality Engineer

Eaton Quality Institute

Southfield, MI 1990–1994

Developed and delivered 30 workshops per year in quality methods such as Taguchi Methods, Statistical Process Control, Continuous Flow Manufacturing, 8D Problem Solving, ISO 9000, Teaming, and Total Quality Management

Developed training course for Theory of Constraints based on book “The Goal”.

Consulted with division manufacturing facilities to implement methodologies post-workshop.

Quality Supervisor

Eaton Engine Components Plant

Saginaw, MI 1989–1990

Supervised four (4) plant quality engineers.

Helped re-establish plant quality system and regain Ford Q1 status after customer audit.

Developed control plan and procedures for manufacturing process.

Completed primary analysis of material study seeking alternative material.

TEACHING EXPERIENCE

University of Toledo

Engineering Instructor – part time. 2007 - Present

MIME department

Teach various classes including Facilities Planning, Statistical Design of Measurement Systems, Engineering Economics, Operations Research, and Statistical Quality Control. Receive consistently high ratings from my student evaluations.

Eaton Quality Institute

Corporate Quality Engineer 1987 -1991

Developed and taught courses in quality methods and techniques. Developed and delivered approximately 30 workshops per year in quality methods such as Taguchi Methods, Statistical Process Control, Continuous Flow Manufacturing, 8D Problem Solving, ISO 9000, Team Problem Solving, and Total Quality Management. Developed training course for Theory of Constraints based on book “The Goal”. Consulted with division manufacturing facilities to implement methodologies post-workshop.

Washington local schools

Substitute math teacher 1983

Executed lesson plans in various high school math courses such as Algebra I & II, Geometry, General Math, and Computer Programming (BASIC).

EDUCATION

GMI Engineering & Management Institute (Kettering University)

M.S. Manufacturing Management

University of Toledo

B.S. Industrial Engineering

Areas of Concentration: Manufacturing Processes, Operations Research

RELATED CONSULTING EXPERIENCE

Fotedar & Associates, LLC

Consultant/Instructor 2011

Developed, modified and gave workshop in Statistical Process Control (SPC) to plant personnel in Houston, Texas for purpose of implementing SPC systems to meet customer requirements.

PUBLICATIONS AND PAPERS

[“Theory of Constraints”]

Training Manual and PowerPoint created for Eaton Quality Institute 1990

MEMBERSHIPS

American Society for Quality Control

OTHER RECOGNITIONS & INTERESTS

Eagle Scout, Troop 136, 1974

Cubmaster, Den leader, metrit badge counselor

Music, audio recording, guitar - electric & acoustic

Golf, club-making, club-fitting

Fly fishing, fly tying, rod-making

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