Quality Assurance Engineer

Objective: To provide hands-on metalworking, electrical, electronic and electro-mechanical device experience to Aerospace/Defense/Automotive Industries on a Contract or Full-Time basis. Apply extensive Manufacturing, Assembly, Quality Assurance, Quality Control and Operational experience to Contractors for Suppliers, Special Processors and Testing Laboratories.

SUMMARY

Hands-on Engineering Professional with proven track record in Aerospace/Defense/Automotive Industries including machining, forming, forging, grinding, cutting, welding, metrology, inspection, materials testing, product verification, project management, Quality Assurance/Control; new product/process implementation, cost reduction and continuous improvement. Trained Six Sigma Champion; proficient with Lean and VSM; proven Kaizen Event leader. Responsibilities have included ADEM, EPA, FAA and OSHA compliance. Responsible for product and process engineering; cost estimating, capital equipment justification, purchase and maintenance. Management Representative responsible for Quality interface with Customers and Regulatory bodies; responsible for RCCA activities. Specific experience and proficiencies include:

AUTOMOTIVE

AEROSPACE

AIAG processes and standards: MSA, FMEA, Control Plans, SPC, Dashboard MOEs etc.

APQP, PPAP, RCCA (8D, 5 Whys)

ISO9001, QS9000, TS16949, ISO 17025

Supply Chain: Selection and Surveillance including Scorecards and Interfacing

OEM and Consensus Product and Material

Standards Development

ISO9001, AS9100, AS9102, AS9120, D1-9000

and customer specific QMS systems

Nadcap MTL; UT, PT, MT NDT; ISO 17025

FAA: FAR Part 21 - PMA; TSO

Special Processes: RCCA (Nadcap, 5 Whys), Heat

Treating and Metal Finishing

Mechanical, Dimensional, Welding, Chemical,

Electronic and Electro-Mechanical Device QA/QC.

CAREER HISTORY

Consulting Engineer 2015

Subject Matter Expert in Manufacturing, Quality Assurance, Inspection, Validation, Systems and Test disciplines. Clients include General Dynamics Land Systems (Verify – Irvine, CA). Products include mechanical, structural, electrical and electro-mechanical components; Source Inspection of welded structural and piping assemblies; wiring harnesses, PCBs and power supplies.

Carpenter Technology Inc., Focus Facility, Athens, AL 2013 – April 2015

Specialist – Quality – Material Testing Laboratory – Specialty Nickel and Cobalt alloy manufacturer. Implemented Met/Chem Lab policies and procedures related to ISO9001, AS9100, AS9120, Nadcap MTL, ISO 17025 and customer standards. Attained approvals and maintained the Met/Chem Lab’s conformance/approvals. Established framework for gathering and analyzing data to effectively detect and solve quality issues to prevent recurrence using appropriate quality strategies, tools, and techniques. Created performance reports for senior management; responsible for Laboratory RCCA activities.

Alabama Aerospace, Military Fastener and Component Distributor, Huntsville, AL 2012 – 2013

Quality Assurance and Control: inspection, supplier and customer liaison and management. AS9120 registered distributor of products for Aerospace/Defense Industries including fasteners, electrical, electronic and electro-mechanical assemblies.

Project Specialist – contracted by VERIFY, Irvine, CA 2011 – 2013

SQAR, General Dynamics Land Systems; performed Supplier Quality Audits and Designated Source Inspections for North Alabama region. Products included mechanical, structural, electrical and electro-mechanical components.

Consulting Engineer 2010 – 2013

Subject Matter Expert in Manufacturing, Quality Assurance, Inspection, Validation, Systems and Test disciplines. Clients included nLogic, Huntsville, AL, and other Aerospace/Defense Industries.

Automatic Screw Machine Products Company, Decatur, AL - www.automaticsmp.com 30 years

Manufacturer of Special Fasteners and precision machined components - Division of Lawson Products, Des Plaines, IL

Vice President Quality Assurance and Engineering Services 15 years

Chief Engineer and Corporate Director of Quality Engineering 15 years

Responsible for corporate QA programs and staff in manufacturing and distribution divisions including inspection and metallurgy laboratories. Responsible for health, safety and environmental, cost estimating, supplier selection/control and manufacturing engineering. Business included multiple US and Canadian JIT sites with suppliers from throughout the US, Europe and Asia.

Implemented ISO 9000 and QS9000. Directed AS9100 and NADCAP implementation/ registration at manufacturing division and ISO17025 implementation at distribution and manufacturing sites.

Oversaw method and cost reduction efforts and made substantial improvements in scrap reduction and rework, equipment and work holding fixtures.

Collaborated with Alabama Technology Network for Lean Manufacturing support. Trained and implemented Lean as the primary business strategy including Visual Operations, Value Stream Mapping and Work Flow Simplification. Other training performed included Blueprint Reading, Shop Math, SPC and GD&T.

Developed internal technical collaboration method and documentation based on Automotive Industry Action Group (AIAG) Advanced Product Quality Planning (APQP) process to bring new products on line while maintaining production with hundreds of existing products.

Experienced with corrective and preventive actions: RCCA, 8D, 5 Whys and Customer Satisfaction processes.

Experienced working with sourcing teams and Asian manufacturers to ensure first-time product quality and fulfillment of contract technical requirements and on-going surveillance activities.

Served as corporate technical liaison to IFI Aerospace Division, NASC (AIA), GIFWG, and SAE E-25 Committees.

EARLY CAREER EXPERIENCE

Various technical, supervisory and management positions with Tenneco-NNS, Westinghouse Nuclear Energy Systems, General Dynamics Electric Boat and Teledyne Brown Engineering in the commercial and naval nuclear power industry in VA, PA, FL, CT and AL. ASME B&PV Code Section III steel fabrication and welding specialist. Projects included constructing off shore nuclear power plants, power plant NSSS components, Nimitz Class nuclear powered aircraft carriers and the Ohio and Los Angeles Classes of nuclear powered submarines.

TECHNICAL SKILLS

Customer Qualification and Supplier Surveillance; ISO, QS9000, AS9100, Nadcap MTL and NDT, and FAA (FAR 21) Automotive and Aerospace Quality Management Systems; employee training in statistical methods, LEAN and QMS.

EDUCATION

Industrial/Systems Engineering Ph.D. Coursework Complete, University of Alabama, Huntsville, 2005

B.S. & M.S. Industrial Engineering, Georgia Institute of Technology, Atlanta, GA

On-going Education: Advanced Statistical Methods, RCCA, Lean and Six Sigma Techniques and Deployment through Boeing, Northrop-Grumman, General Dynamics, Caterpillar U, ATN and the University of Alabama. Various Management Courses, Team Building and Leadership Courses through Dale Carnegie.

PROFESSIONAL AFFILIATIONS

Life Member, Society of Manufacturing Engineers (SME); Senior Member, American Society for Quality (ASQ). Adjunct Instructor at The Apprentice School and John C. Calhoun Community College; Examiner, Alabama Quality Award 1999 – 2003 and 2010 – 2011.

SAE International (SAE): Member of SAE E-25 Propulsion Standards Committee, SAE G-21 Counterfeit Material Committee; National Aerospace Standards Committee (AIA); Government/Industry Fastener Working Group and Aero Mechanical Fasteners Requirements Group; corporate technical liaison to IFI Aerospace Division.

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