Manager Quality

William S. Bernay

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

Painesville Township, Ohio 44077

440-***-**** cell or ********@***.***

PROFESSIONAL SUMMARY

A hands on Technical Manufacturing Professional with proven background in Operations, Quality, and Engineering with extensive experience successfully managing manufacturing operations including union and non-union facilities, implementing Quality Systems, TS/ISO Registrations, new product and tooling launches, continuous improvement programs, cost reduction initiatives utilizing Six Sigma programs and lean manufacturing principles, seeking a high level opportunity in Operations Management, Engineering or Quality Management.

PROFESSIONAL EXPERIENCE

CLIFTON STEEL COMPANY, Maple Heights, Ohio April 2009 to June 2016

Clifton Steel Company is a manufacturer of abrasion and wear resistant steels, specializing in impact resistant steel for military and ballistic armor applications. Since 1971, the company has provided personal service and steel fabrication expertise to a variety of industries including military, aggregates, mining, steel, glass, paper, scrap recycling, and railroad

Plant/Manager

Responsible for the overall operation of a multi-shift manufacturing facility, including EH&S, Quality, P&L, plant equipment and facilities maintenance, and scheduling while overseeing 70+ union and salary personnel

Directed the operation of two Heat-Treat furnace lines producing military ballistic armor up to .5” thick and 60” wide, at a production rate of 1 ton per hour each. Up 15% from 2015 through Value Stream Mapping and Lean manufacturing principles

Increased up-time of Heat-Treat furnace, quench, and temper line by 20% by preventive maintenance programs and continuous improvement upgrades to equipment

Increased On-time delivery of all sales line items to customers by 30% by introducing a daily multi-disciplinary meeting and establishing key metrics, roadblock review, and action item follow-up

Active member of all Board of Directors Meetings since the inception of the Board in 2012

Represented the company on the 2013 Collective Bargaining Agreement negotiations with the International Brotherhood of Teamsters Local 507, successfully navigated a labor interruption with minimal loss of production and no meaningful effect on customer delivery

Instrumental in the evaluation, selection, and implementation of an new ERP/MRP manufacturing system, moving from an outdated Intuitive to EPICOR in October of 2014

Essential in the introduction and registration to ISO 9001:2008 Quality Standard in 2012, including a successful re-registration in 2015

Responsible for the development and implementation of machined products within the Maple Heights Division by overseeing the acquisition of two Vertical CNC Machining centers and one Horizontal CNC machine, while relocating the stainless steel and aluminum operation in Pittsburgh, PA to Maple Heights, OH

Upgraded the CNC Plasma Burning capabilities of Clifton Steel with the addition of a High Definition Plasma Table (10’ x 20’), including a Down Draft System with Dust Collector

SHILOH INDUSTRIES INC. Valley City, Ohio August 2003 to April 2009

$500 million Tier 1 supplier of laser welded, mechanical blanks, stampings and welded assemblies to the automotive, lawn and garden, and appliance industries. A technological market leader in laser welded blanks, welded chassis components, and stampings.

Plant/Operations Manager – Medina Blanking Division January 2008 to April 2009

Responsible for P&L of multi shift blanking and laser welding facility overseeing manufacturing, quality, engineering, tooling, material procurement, and finance – $60 million (FY08) annual sales with over 160 personnel

Responsible for development and implementation of operating budget and executing Overall Corporation strategic visions and plans

Actively involved in forecasting product sales and material needs including establishing daily production metrics and review of constraints for blanking presses and welding lines. Review and control of inventory and raw material purchases to exceed budgeted inventory turns

Utilize Lean Manufacturing and Six Sigma techniques to improve efficiencies, reduce waste and continuously initiate and execute operational efficiency improvements in the manufacturing operations, FY09 YTD savings above $500K

Identification and implementation of Value Added / Value Engineering opportunities to eliminate customer demanded financial givebacks without cost penalty on bottom line financials

Experienced in standardizing work, development of best practices, establishing process controls, identifying waste in production for coil processing, blanking, stamping, welding, assembly, fabrication and heat treating processes

Manager of Quality – Cleveland Manufacturing Division August 2003 to January 2008

Provided leadership and direction to a Quality Department staff of 5 Quality Engineers, 2 Quality Supervisors, 2 CMM Operators, and 11 Plant Auditors while championing product and process quality efforts throughout the entire organization.

Successfully converted Shiloh’s-CMD QS9000 quality system to a process oriented TS16949 automotive standard to be awarded a registration certificate within 8 months

Redefined the internal and external audit function to a results driven standard with emphasis on product quality and process performance

Established and maintained “Six Sigma Defect Level” in external product quality, zero to single digit ppm performance as a tier 1 automotive stamping and welded assembly supplier

Implemented an internal nonconformance improvement program with team involvement, communications, measurements, 8D problem solving, and process controls, reducing ppm levels by over 60%

Assisted and provided manufacturing/quality leadership to Materials and Logistics Team to improve product delivery performance and maintain 100% ratings at Ford, GM, and Chrysler.

Directed and maintained systems to effectively measure and control incoming product quality costs of material and components and improve overall product yield and quality

MIDLAND STEEL PRODUCTS CO., Cleveland, Ohio July 1998 to June 2003

Major North American supplier of truck frame rails and frame assemblies to the medium and heavy-duty automotive industry.

Director of Engineering

Responsible for Product, Manufacturing, and Tool Engineering of all products throughout the entire corporation

Coordinated the successful tooling transition and rebuild of the GMT 560 Medium Duty blanking, piercing, and forming tools PPAP’s achieved within 15 weeks

Overseeing a $1 million tooling program ($54 million annual sales) to launch the GMT 560T “Isuzu” Medium Duty Truck Program, tooling completed within 18 weeks

Involved with many cost reduction and product improvement programs within engineering, manufacturing, and quality departments

Plant Manager

Responsible for the overall operation of the Solon, Ohio, heat-treating facility, at the same time, maintaining the responsibilities of Director, Quality Assurance for the entire corporation

Increased production output of the combustion heat-treat facility by 20% by establishing mutual trust and cooperation with the UAW, while reducing manpower over 15%

Reduced scrap 70% with the aid of statistical tools, problem solving techniques, operator involvement programs, and modifications to job responsibilities

Actively participated in the successful negotiation of a 4-year Solon labor contract with UAW (January 2001), with minimal salary increases and allowed for modified work hour schedules.

Director, Quality Assurance

Directed the efforts of Quality and Engineering Departments of the Cleveland facility consisting of 13 professionals and 19 Union Inspectors. Responsible for multi-plant Quality departments

Satisfied the exit criteria, of the inherited, General Motors “New Business Hold” in 5 months through 8D problem solving and quality system development. Presented statistical evidence to GM.

Drove the successful re-certification efforts to QS 9000 Third Edition, previously under suspension

Reduced internal scrap by 60% using statistical process control, team problem solving, and disciplined use of control plans.

PMX INDUSTRIES, INC. Euclid, Ohio 1997 to 1998

International primary copper and alloy producer of coil, strip, coinage, and ordnance.

Manager, Quality Assurance

Rebuilt Quality Department, to 11 professionals, reducing the internal rejection by over 30 %

Led ISO 9002 Registration process. Coordinated company wide efforts towards a 12-month conclusion through Document and Record control, Advanced Product Quality Planning, and Production Part Approval Process

REVERE COPPER PRODUCTS, INC. Rome, New York 1990 to 1997

Leading primary copper and alloy producer of coil, strip, bar, sheet, and specialty products

Metallurgical Manager, 1994 to 1997

Directed a Quality Department of 16 professionals, establishing a Quality and Operating system successful in ISO 9002 Registration.

Established a process control program for tool life, chemicals, and lubricants, reducing production interruptions and quality deficiencies.

Manager, Process Engineering, 1992 to 1994

Managed 3 Process Engineers responsible for creating all manufacturing methods

Developed a measuring and test equipment control system eliminating measurement inaccuracy

EDUCATION

University of Dayton, Dayton, Ohio

Bachelors Degree in Industrial Engineering Technology

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