LEIVA URMAN

**** ******* ****** **

Newton, NC **658

E-mail: acs6zf@r.postjobfree.com Cell: 704-***-****

SUMMARY

Highly experienced Quality Assurance Manager (CQE, CQA) and Continuous Improvement leader (ASQ-certified Six Sigma Black Belt) with strong background in operations, organizational development and industrial engineering. Expertise in statistical methods, SPC, plans of control, DOE and data analysis. Experience managing international suppliers and global customers in a broad range of industries and manufacturing processes. Obtained ISO9001:2008 Internal Auditor RABQSA certification in 2012. Fluent in Spanish and English.

EXPERIENCE SUMMARY

SPECIAL METALS WELDING PRODUCTS COMPANY - Newton, NC 09/2013 – present

Manufacturer nickel alloys welding consumables

Quality Assurance Manager

Responsible for conformance to required industry quality management systems requirements; these included ISO9001, ASME Section 3800 of the Boiler and Pressure Vessel Code. Participation in continuous improvement activities and day-to-day oversight of the department. Supervised two salary and one hourly personnel. Activities include:

Lead project for product quality improvement – successful implementation is estimated to generate additional sales of $1.6mm. While project was under a Kaizen activity, Six Sigma tools were used.

Restructured department’s work schedule to provide 7-day support to manufacturing resulting in annual overtime reduction of over 240 hours.

Coordinated effort to improve first pass yield (error free) of certified material test reports. 2015 result is over 97% FPY.

Led product certification efforts with world recognized agencies such as American Bureau of Standards. These certificates allow for increased sales, expect $400m additional in 2016.

Improved the nonconforming material handling process. This involved establishing a Materials Review Board with authority for all dispositions – Materials Planning, Quality and Production are the member organizations. Result is a more effective resolution of recurring issues and disposition of material.

HUQSVARNA – Orangeburg, SC 07/2011 – 09/2013

Manufacturer of fuel powered lawn care products

Process Owner Quality Systems

Responsible for providing quality assurance support (Quality Engineering, APQP, Process and Internal Auditing) for the implementation, auditing, registration, maintenance, and on-going effectiveness of the Quality Management System compliant with ISO 9001:2008. Supervise three salaried personnel. Current activities include:

Lead implementation and maintenance of the Layered Process Audit (LPA) program.

Leading new supplier through the APQP/PPAP process for qualifying OSB crating

Mentored three Six Sigma Green Belt teams with estimated savings of $180k/year in 2012

Lead development and implementation of processes and procedures to assure compliance and registration to ISO 9001:2008 standards. Using the QSI System for paperless documentation.

Maintain the internal auditing process focused on control of nonconforming materials process.

-Manage consolidation of databases and data collection systems under the QSI Systems

-Lead interplant auditing team in performing audits for compliance to ISO 9001 standards

ZIMMER. – Statesville, NC 04/2011 – 05/2011

Manufacturer orthopedic surgical products.

Senior Quality Assurance Engineer – Contractor

Member of transfer team for the non-sterile soft good products. My responsibilities focus on compliance to internal policies and product quality. Activities included:

Gap analysis of quality metrics

Risk analysis – process FMEA

Review and recommend changes to product drawings

Prepare first article protocol for products and packing requirements

SAFT AMERICA, INC. – Valdese, NC 2007 – 2010

Design, development and manufacture of high performance primary lithium and lithium ion rechargeable batteries for industrial and defense applications.

Quality Assurance Manager

As management representative, responsible for compliance to the ISO001:2008 quality management system. This included managing traditional quality assurance functions such as quality engineering, incoming inspection, non-conforming material dispositions, CAPA program, customer complaints and internal auditing system. Host customer and third party audits. Assured QMS supported FDA requirements for customers with medical applications. Manage two salary and four hourly associates. On temporary basis, led lean activities such as point Kaizen (line organization events), 5S and SMED.

Revised incoming inspection skip lot plan, increased frequency of supplier audits, closer monitoring of high volume and repeat offender suppliers led to a reduction by 30% in frequency of non-conforming materials.

Managed internal auditing system. This included performing process audits and follow up on audit findings.

Led Customer Satisfaction PDCA team focused on reducing response time to the customer. Reduction was 12%.

Expanded use of SPC software to capture data from added equipment and new processes.

Redesigned the supplier audit plan to allow for either on-site audits or self audit by supplier.

Certified Quality Management System to ISO9001:2008 standards with zero deficiencies.

Working with Purchasing, develop audit plan for suppliers. This included auditing potential suppliers, routine audits of major suppliers and audits to focused on supplier performance.

Reduced cost of destructive testing by $47,000 per year while maintaining process capability. Used SPC software to identify processes with high Cpk and prioritized efforts based on dollar impact.

Reduced calibration costs by $18,000 per year by building capability to perform calibration in-house, increased verification processes before performing calibration and reviewed usage prior to routine calibrations.

Redesigned 5S program by making the program team based by area and providing incentives for exceeding goals.

Completed SMED events and refined those already in place.

Implemented electronic web based system to manage and maintain Material Safety Data Sheets.

WEBSTER INDUSTRIES, INC. – Montgomery, AL 2000- 2007

Manufacturer of plastic trash bags, food contact products and packaging solutions for our private label and commercial/industrial business partners and our own value brands.

Plant Quality Control Manager and Reprocessing Manager – 2006 – 2007

Responsible for product quality and product safety. Also managed Reprocessing Department, which compounded 30 million pounds of internal and purchased scrap annually into raw material for reuse. Supervised four salary direct reports and 43 hourly employees.

Reorganized Quality Department to increase focus on process monitoring and eliminated two positions.

Led cross functional team to reduce leaking defects on food storage bags by 11%.

Operations Manager, Liners and Reclaim – 2004 - 2006

Managed manufacturing of plastic can liners and reprocessing of internal and purchased scrap. Nine salary direct reports and 240 hourly employees.

Reduced cost of blended material via introduction of lower cost substitute without adverse effects in quality and processing. Expect annual cost savings in excess of $250,000 by the end of 2005.

Corporate Quality Manager – 2000 - 2004

Position was vacant for almost 900 days.

Five salary direct reports and 17 Quality Assurance Inspectors.

Six Sigma certification project resulted in savings over $300,000 by reduction of scrap and plastic pellet defects.

Reduced finished product holds by 20% by implementing procedures focused on prevention of quality defects

Initiated use of acceptance sampling plans for purchased products reducing converting problems

Applied Six Sigma methodology to implement Good Manufacturing Practices program. Obtained rating of “Excellent” in the first independent audit.

FORT JAMES CORPORATION 1973-2000

Note: Georgia Pacific acquired Fort James Corporation in 2000

Manager, National Quality Assurance - Dixie Products – Easton, PA 1987-2000

Managed the application of standard quality assurance procedures and methods at nine plants with sales of $800 million. Managed staff of four.

Directed and managed compliance with GMP HACCP for all facilities. Including IMS and Kosher certifications.

Implemented SPC in a testing laboratory, improving test results and equipment reliability.

Performed system audits at the cutlery facilities to ensure compliance with Dixie policies. Including audits for compliance with GMP, HACCP, IMS and Kosher requirements.

Developed and implemented an approach for certification of newly installed equipment, enabling identification of problems in the early stages of production.

Used Design of Experiments (DOE) techniques to improve processing conditions leading to significant reduction in customer dissatisfaction.

Led centerlining technique implementation on a 96-cavity mold reducing cycle time by 20% for the injection molding line.

Coordinator, Organizational Development - Naheola Mill Towel and Tissue Division – Pennington, AL 1986-1987

Led programs that increased employee participation in process improvement and quality of work life.

Facilitated team building and task forces.

Co-led implementation of a high performance work system in the Accounting Department.

Developed and conducted the first SPC training program for Bleach Plant Operators focused on individuals and moving range charts.

Facilitator for the Accounting and Finance Departments of the Towel and Tissue Division

Quality Engineer - Naheola Mill 1982-1986

Focused on data analysis, supervised eight hourly inspectors

Responsible for test equipment in the four testing laboratories

Member of product development and commercialization team commercial paper towels

Productivity Engineer - Naheola Mill 1980-1982

Developed and maintained production standards for all Mill operations.

Led implementation of $750,000 reduction in packaging and shipping costs through the redesign of corrugated containers.

Member of three-man task force that developed and implemented a quality control program, reducing costs $30,000/year.

EDUCATION

B.S. Engineering Operations, North Carolina State University

B.A. Liberal Arts, North Carolina State University

PROFESSIONAL DEVELOPMENT

TQM, Statistical Process Control, Design of Experiments,

Facilitator Skills, Consulting Skills, ISO9000, Injection Molding

ADDITIONAL INFORMATION

Certified Six Sigma Black Belt by ASQ

Certified Quality Engineer by ASQ

Certified Quality Auditor by ASQ

RABQSA Internal Auditor Certification (ISO9001:2008)

Bilingual in Spanish and English

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