Quality Assurance Manager

John Berk

*** **** ****** *****, *********, PA **904 T: 814-***-**** *********@*******.***

Quality Assurance Professional

Quality Assurance / Process Improvement / Operations

Career Summary:

A growth-oriented and highly talented Quality Assurance professional with a strong background in Quality Management Systems, Lean, Six Sigma, manufacturing/remanufacturing process engineering management, safety and environmental compliance, and project management. Extensive experience in machining, welding, fabrication, stamping, heavy truck bodies, assembly, new product roll-outs; and leading cross-functional and multicultural teams. Over 25 years of experience in this domain, as well as, excellent communication and leadership skills.

Job Skills:

Quality Assurance

Quality Assurance/Kaizen/ISO 9001, AS 9100, TS 16949

DoD

Automotive

Manufacturing Engineering

Certified Six Sigma Black Belt

TPS/Lean Manufacturing

Cross-Functional/Multicultural Team Building/Leadership

Intense Customer Focus

Change Management

Project Management

Continuous/Process Improvement

Aerospace

Other Skills:

An experienced team leader with the ability to initiate/manage cross-functional/multicultural teams and multi-disciplinary projects, and to deliver cost reductions

Excellent personal communication skills (both written and verbal)

Project management skills: influencing, leading, negotiating and delegating abilities

Dedicated to the training/development of subordinates and associates

Excellent, experienced coach/mentor

Experienced and comfortable in the global marketplace and multicultural environments

Conflict resolution

Adaptability and tolerant to stressed situations

Creative thinking and organizational skills

Effective listening skills

Decision making, networking, and negotiating skills

Determination and diplomacy skills

Focused orientation to satisfy customers’ requirements

Experienced and proficient presenter/speaker

ACCOMPLISHMENTS

DESIGNED AND IMPLEMENTED ISO 9000, TS 16949, and AS 9100 quality management systems in over 50 organizations, in a wide variety of industries, worldwide. Result: 100% successful registration and productivity inceases as high as 20%.

LED over 50 Lean Manufacturing projects and interventions in manufacturing, and service organizations (including unionized organizations) in the USA and worldwide. Result: Established new cultures, achieved reduced production costs, and shortened cycle times – as much as 11 weeks.

LED over 30 Six Sigma/Kaizen events. Result: Achieved, through the implementation of process improvements and integration of new technologies, marked reductions in scrap, waste, and rework – as high as 40%.

DESIGNED and IMPLEMENTED a plant-wide TPM system, which included predictive maintenance systems. Result: reduced downtime by 20% and reduced the cost of maintaining production machinery and equipment by 15%.

ANALYZED machine and equipment designs and associated processes and procedures. Result: Attained productivity improvements ranging as high as 20%.

ANALYZED quality management and supplier audit/evaluation systems. Designed and implemented effective Supplier Evaluation Systems; improved auditor training and development programs. Result: Increased reliability by 35% and reduced non-complying product by 40%, while reducing the cost of quality.

LED several Supply Chain process improvement interventions. Result: Reduced processing time for inbound materials by 30%.

PROFESSIONAL EXPERIENCE

Penn Machine Company April 2012 – June 2014

Served as the Manager of Quality Assurance, with responsibility for quality assurance (including ISO 9001, warranty activities, and gage lab operations) for three manufacturing plants in two states. Reduced the cost-of-quality from 2% of sales to .37%. Achieved ISO 9001 registration for one plant, maintained AAR registrations (including re-registration) for two plants. Led three Lean/process improvement initiatives, resulting in a reduction in process time of a painting operation of 40%; an improvement of ergonomics/safety and a cost reduction of 20% in an inspection operation; and reducing the processing (assembly) time of a product line by 30%, while significantly reducing the risk of injury to the employees.

JB Associates – Johnstown, PA 2007 – April 2012

As a self-employed consultant, provided operations, manufacturing, and quality assurance management services, including: process improvement (Lean, Six Sigma, Theory of Constraints, etc.), quality assurance (ISO 9000, AS 9100, and ASME), manufacturing engineering, project management, and workforce development services for a variety of manufacturing organizations, both union and non-union, in the public and private sectors.

Served as the Operations Manager for truck body manufacturer with responsibility for manufacturing, quality assurance, and engineering. Led the transition to Lean manufacturing, ISO 9000 quality system, and structured root cause analysis.

Served as the Quality Assurance representative for a defense contractor and was responsible for all quality assurance and testing of the development and insertion of a technology upgrade into an existing underwater weapons system for the Naval Underwater Warfare Center and the preparation of a defense contractor for ISO 9001 registration and process improvement interventions.

Served as the Site Manager and was responsible for the operations of two sites (Windber, PA and Uniontown, PA), which designed, developed, and integrated advanced communication systems for the DoD. Responsibilities included P&L, budgets, capital acquisitions, facilities maintenance, purchasing, manufacturing, and HR. Established academic and cross-training programs (and a new culture), Lean Manufacturing, Theory of Constraints, and Six Sigma process-improvement methodologies. Authored and presented a Supervisory Development Program to incumbent supervisory personnel. As a result, a contract for two communications systems vehicles was produced within budget and on time, despite very short notice and numerous change orders. Another contract for five Command Operations Centers, totaling $7M, was delivered four months early and under budget, despite significant delays resulting from supply chain interruptions. Negotiated a contract to produce ATV vehicles for the commercial marketplace and saved the company over $1M. Led the effort for ISO 9001/AS 9100 registration.

MountainTop Technologies, Inc. – Johnstown, PA 2005 – 2007 (18 months)

Served as the Director of Process Improvement and was charged with developing a new business initiative involving process improvement consultation for DoD and commercial clients. Wrote the text for a process improvement methodology, which is entitled “Comprehensive Process Improvement” (CPI). CPI is based on a blending of TPS/lean manufacturing principles, Six Sigma/Kaizen production and process problem solving, TOC principles, change management and employee and management development programs. Facilitated process improvement interventions at client sites, authored and presented training programs, and supported business development activities. Worked with Congressman Murtha’s staff to assist DoD contractors in improving the productivity and quality of their manufacturing operations.

Custom Technologies, Inc. – Glen Rock, PA 1989 - 2005

Founded and was the President of this management consulting firm, which performed corporate turnarounds, mergers and acquisitions, provided transitional management services, and provided quality assurance and process improvement interventions. These were accomplished through a blended combination of TPS/Lean manufacturing principles, Six Sigma/Kaizen production and process problem solving, Theory of Constraints principles, change management and employee and management development programs. ISO 9000, QS 9000, and AS 9100 registration preparation services were also provided. Client organizations were in a wide range of industries (including DoD), both domestically and internationally.

PRIOR EXPERIENCE

Commercial truck body fabrication and repair (including painting, lettering, and signage); Manufacturing of fire apparatus (including painting, lettering, gold leaf, and signage), Steel; aluminum, and plastic fabrication; Certified Welder; Journeyman Machinist; Maintenance Mechanic/Manager; Process/Manufacturing Engineer; Machine Design Engineer; Project/Process Engineer, Project Manager, Engineering Manager, Manufacturing Manager, Plant Manager; VP Manufacturing; Quality Assurance Manager; VP Operations.

EDUCATION

M.E.A.D. – Master of Engineering Administration, George Washington University

B.S. - Mechanical Engineering, Penn State University

A.E. - Mechanical Engineering Technology, Penn State University

Registered Lead Assessor - ISO 9000 - Institute of Quality Assurance (IQA), UK

Registered Lead Assessor - QS 9000 - Automotive Industry Action Group

Registered Tutor for ISO 9000 Quality Management Systems - IQA, UK

Certified Six Sigma Black Belt

Toyota Production System (TPS) training –Toyota Motor Company

MILITARY EXPERIENCE

US Navy – 1969 through 1973 – Aviation Crash Firefighter and Corpsman. Achieved the rank of E-5, and an honorable discharge. Earned the Navy Commendation Medal and was chosen as Sailor of the Quarter.

SERCURITY CLEARANCE

Secret clearance, inactive

Passport is current

PROFESSIONAL AFFILIATIONS

American Society of Mechanical Engineers

Society of Manufacturing Engineers

American Society for Quality

Institute of Quality Assurance – United Kingdom

Lifetime Member of Penn State University Alumni Association

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