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Quality manager / Quality Engineer / Launch Engineer

Louisville, Kentucky, United States
October 13, 2016

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Edward Shewmaker

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

Lebanon, KY ***33


Summary of Skills

Toyota Production System (13 Years) TS 16949 Audit Prep / Execution

ASQ Certified Quality Manager # 8751 Supplier Quality Engineer

5 why/ 8-D /5P/ problem formats Layered process audit design and management

Model Launch, APQP, Control Plans Subordinate Training Team Building

Project Management (Model Launch/ Lean Manufacturing Workshop Leader

Facility Startup / New Equipment) Multifunctional Worker Training

Continuous Improvement Leader Process Layout and Design

Assembly, Welding, Molding and Stamping Presentation and Mtg Facilitation Skills

5-S Implementation Experience PKT (Practical Kiazen Training)

3D modeling intermediate (Catia / JT to go ) Statistical process evaluation (Minitab)

Fixture verification / Eng. change Mgt. SMED Training

Lean Manufacturing Consultant / Coach Production Process Improvement

American Society Quality # 63241309 Identify and Eliminate Unsafe Work Practices

Certified Internal Auditor QS9000 New Facility and New Process Start-Up

Computer Skills (MS Office, Catia, DMV, MS Project) SPC / Data Collection and Display

Technical Drawings and TIS understanding Manage Safety, Quality, Cost, Delivery & HR

TS16949 / ISO9000-2002 / ISO 14000/ CFR21 Weld Integrity testing / cut and etch etc.

Machining / Welding / Plasma and Gas cutting CMM / Charts / Graphs / Reports

Relevant Experience

Firestone Industrial Products, Williamsburg, KY(contract) 4/2016-Present

Non-conforming purchased part reduction

TS16949 audit preparation

Magna International, Bowling Green KY (contract)

Gage /fixture / Eng. change (ECN) coordination Ford Super duty launch 12/2015-4/2016

Precision Die Cast, Russellville Ky(contract) 82015-12/2015

Interim Quality Manager

Jacobs Vehicle System, Bloomfield CT (contract) 6/2015-8/2015

Launch Liaison Hino Truck

Launch of grey iron Compression brake

Honda Motor Manufacturing Alabama (contract) 6/2014- 6/2015

SQE Purchasing New Model Parts Quality PIC

PIC on 16.5 MY Ridgeline launch 1st non prototype development launch

Customer representative to weld and stamping suppliers for new model readiness reviews… Magna,/JSC/Unipres/Topre/Shiloh Industries/LW Eng

Audit and Verify Supplier Quality adherence to CTQ control PIST Score Verified capacity and process Capability through observation audits and data review for all weld/stamping suppliers

General Motors, (contract) 7/2013-1/2014

Operations Group (Distressed Supplier Response Team) / Quality and Productivity problem resolution

Supplier Interface…Magna /ZD Metals/Cooper Standard/Plasan

Multiple locations and commodities (domestic and international)

PPAP review / problem report countermeasure verification..

Westport Innovations, (Ford QVM) Louisville Ky (contract) 4/2013-7/2013

Corporate Quality Liaison / Ford QVM audit liaison

QVM certification /audit completion with no findings.

Process mapping / work instruction critique / layered process audits.

General Electric Corporation, Louisville Ky 5/2012-3/2013

Quality Engineer / Lean Manufacturing Implementation Specialist / Supplier Interface

Dimensional confirmation appliance components. (refrigeration)

Process mapping for extrusion, Thermo forming, injection molding, pre and post foam

case and door, sealed systems and charge station and final assembly.

Implementation of IPC-A-610 soldering and brazing standards.

Harley-Davidson, Kansas City MO (contract) 12/2011-5/2012

Purchased Component Quality Engineer / New Product Launch / Engineering Change Implementation

Control supplier defect flow out by maintaining scorecards.

Critique and evaluate supplier problem solving efforts for effectiveness.

Perform supplier process audits as necessary and launch readiness audits.

Manager all phases and components of PPAP approval.

Cummins Corporation, Seymour IN (contract) 3/2011-11/2011

Supplier Quality Improvement Engineer /Expansion preparation Team/ New Product Launch

Diesel Engine Machining and Assembly

Control and reduce dollar value of on hand defective supplier components.

Secure effective containment and corrective action plans (8D) for defects fromsuppliers to prevent reoccurrence.

Conduct supplier audits for countermeasure verification. Report supplier PPM to corporate level mgt.

Critique effectiveness of current supplier control plans.

Launch of Cummins new wed based defect communication system (CQMS).

Toyotomi America, Springfield KY (contract) 1/2011-3/2011

Launch Engineer / Quality Engineer /Launch Engineer / Shift Supervisor

Automotive stampings and welded components

Coordinated pre production trials components for upcoming 2012 Toyota Camry launch.

Performed required APQP activities for prototype build for 2012 Toyota Camry launch.

Led 2nd Shift production activities during launch.

Coordinated HVPT trials for new Camry components.

Addressed customer quality concerns and provided written documentation of countermeasure activity.

JCIM, Louisville, KY (contract) 4/2010-10/2010

Automotive interiors injection molding

Coordinated transfer of Toyota 5 high volume components into JCIM from another supplier without interruption to OEM. Completed all PAPP documents, coordinated all color/ grain trials and approvals, developed work instructions and inspection instructions.

Performed all required APQP activities for prototype build for 2011 Toyota Camry launch. 20+ parts in four colors all requiring color, texture and dimensional and functional confirmation.

Performed DOE on two existing process targeting cycle time reduction. Completed dimensional layout and submitted necessary engineering process change documentation to OEM.

Southern Indiana Plastics 4/2009-1/2010

Quality Manager / Project Engineer / Quality Engineer

Automotive interiors injection molding.

Led company through TS 16949 recertification (Underwriters Laboratory Dec. 09)

Adjusted material and finished goods flow within the plant to accommodate first in first out inventory control, and establish product traceability and operator accountability.

Improved incoming raw material inspections process and verification

Responded to and implemented necessary countermeasures for any customer quality complaints.

Nakagawa Sangyo Corporation, Lebanon, KY 3/2007-10/2007

Quality Manager / Quality Engineer

Stamping and welding operations of automotive exhaust and ATV exhaust and suspensions components.

Developed and monitored daily activities for all inspectors.

Displayed quality and production results data to improve awareness and accountability.

Facilitated quality meeting / audit countermeasure meeting.

Coordinated all new product launch activities for Honda exhaust components APQP/PPAP

Contract Consulting/Quality& Process Engineering /TPS Training 1/2001-1/2006

RWD Technologies, Auburn Hills MI

Senior Lean Mfg. Consultant, Daimler-Chrysler Account

Product Action International, Vance AL

Supplier Quality Engineer / Location liaison @MBUSI, Johnson Control, Delphi


Continuous Improvement Coordinator / Supervisor / Lean ManufacturingPrinciples

Summit Polymers, Mt. Sterling, KY

SupplierQuality Engineer / Problem Solving Instructor/ 5S policy Implementation/CMM

Hendrickson Truck Suspensions

SupplierQuality Engineer / Problem Solving / Welding Integrity/CMM/QS certification

ToyoLex Industry Corporation Nitti Denko, Lexington KY 1/ 1999-8/1999

Production Manager / Quality Manager / Product Engineering

Managed the initial plant start-up – including production transfer from Japan, new equipment installation, and drafting of plant quality manual. Led the plant through ramp up phase to multiple daily shipments to TMMK, TMMI, TMMC, and NUMMI.

Prepared the documentation necessary for ISO 9002 certification.

Developed the H/R policies, hiring practices and promotion criteria for the new U.S. workforce.

Implemented initial 5-S policy and practices.

Completed all necessary SQAM documentation necessary to be a tier one parts supplier to Toyota. Led the 1st HVPT trial at the new facility.

Represented ToyoLex at the annual Toyota Suppliers Conference in San Francisco.

Toyota Motor Manufacturing Kentucky, Georgetown KY 2/1988-1/1999

Paint Shop Group Leader / Expansion Planning Team Coordinator / New Model Pilot Team Supervisor /

Inspection Group Leader / Assembly and Paint and Welding Repair Group Leader

Trained in Japan on the development and proper use of Standardized Work / Job Instruction Training / and Job Breakdown Sheets necessary for the smooth start-up in 1988. Made multiple working visits to Japan for training and equipment tryouts.

Recognized for performance through the company promotion and bonus programs. Assigned to lead the Paint Inspection and Repair Department during plant expansion and new model launch. Helped develop inspection standards for the newly developed Avalon based on its targeted market segment in Japan. Visited ports facility at Tahara and Yokohama and observed Crown production at Kyushu plant.

Drafted 5-S policy for Plant 2 Paint building on lessons learned from Plant –1 start-up. Implemented matrix for T/L level to support overall annual plan.

Responsible for departmental budget forecast and reduction including industrial cleaning cost, overtime premium, raw material usage, rework cost and scrap cost. Implemented programs to control reduce or better understand these costs, using data provided at the closest possible point to the issue.

Led new facility start-up team – Equipment, Material and Quality Confirmation Trials. Responsible for 50 process layout and design, staffing, training, time studies and ergonomic evaluations.

Taught Level –2 Problems Solving to Paint production teams.

Led JD Powers Quality Improvement task force focusing on UIN (interior noise reduction).

Education and Training

Almeda University (Louisville, KY campus) 2000-2005

Bachelors Business Administration/Engineering Technology

McKendree College, Lebanon IL (Louisville, KY campus) 1994-1999

Bachelors Business Administration / Management (120 hrs)

American Society For Quality 2001-Present

Certified Quality Manager # 8751

Manager of Organizational Excellence #8751

Society of Automotive Engineers (SAE) 2000-Present

Member since 1998

MCAV Technology Center 2004

Mig Welding Training / Hendrickson Truck Suspension


United States Navy 1980-1986

Operations Specialist ‘A’ School Dam Neck VA

Track Supervisor School, Point Loma CA

Air Strike Controller School, Point Loma CA

Firefighting and Safety Training, Treasure Island CA

Employee Development and Training 1988-2006

Job Instruction Training Check Fixture Design Lean /Sigma Workshop UAH

Process Layout Employee Recognition Diversity Training

Standardized Work Violence in the Work Place Salary Administration

TS16949 Training Kiazen Training Sexual Harassment Training

SMED One Piece Flow

Resume Supplement

Quality Engineering / Quality Management / Process Engineering / TPS Implementation

Paint Systems / E-Coat processes/Process Engineering

Set up system and schedule for film build audits after each stage of paint operations.

3 Pipe circulation system for H2O borne paint system (TMMK)

Infrared (BGK) lamps implementation for increased repair efficiencies (TMMK)

Testing installation and tryout of HVLP manual spray equipment (TMMK)

Manual conveyor system for shell body movement. (TMMK)

Assembly Equipment Installation and tryout

Installed assist equipment and poke yoke device on sunroof assembly line. (TMMK)

Set up torque check station to eliminate rework of sunroof installation. (TMMK)

Assisted in the procurement of “Foam In Place” machine led mold and fixture debug activity.(AIT)

Lamination process layout and design(Toyolex)

Welding Process

Developed roving “chisel check” procedure to monitor manual and robotic weld integrity.

Developed receiving inspection procedure and criteria for coil steel deliveries

Utilized vision system for robotic weld placement and failsafe feature.

Organized inspectors daily checks for improved control and reliability.

Stamping Equipment / Die Set Up / Design

Part nesting, die layout and packaging proposals.

Akebono 2 ton and ton presses – contracted shipping and installation, led tryout and coordinated production ramp up for over 20 foam, butyl, and plastic parts supplied to TMMK, TMMI, TMMC, NUMMI. (ToyoLex).

Led die changeover time reduction activity at Master Form, Inc. (GM / Allison Transmission supplier)

Facilitated die changeover time reduction activity at Chrysler’s Sterling Stamping facility.(RWD)

Lean implementation

SMED - Trained on kitting and production leveling. (TMMK )

Implemented visual factory concepts (Inventory min/max, 5S, one piece flow, kanban system) (ToyoLex, AIT)

Developed and displayed and reported on key performance indicators as a basic management tool. ( All positions )

Training and Subordinate Development

Taught level 2 problem solving. (TMMK)

Standardized work instructor (RWD)

Mentored 7 supervisors and future manager while leading the inspection and repair area at TMMK.

Taught quality standards, productivity indicators, rapid response to internal and external problems and reporting process at daily plant quality audit meeting using A-3 format.

Quality Engineering Testing Experience

Set up gauge calibration & R&R schedule (gage-pak software) for QS 9000 cert.

Fulfilled PPAP requirements: documentation, testing, trials, submission and approval

APQP for new product launch. (TMMK, Summit, NSU)

Maintain calibration schedule for micrometers/calipers /scale/quick check gages.

APQP Completed all requirements per Toyota SQAM manual part approval process.

Weld integrity check: cut / etch, chisel check, photo check.

Paint properties check, color, gloss, smoothness, ROI, adhesion.

Professional References

Name: Reid White

Phone Work 205-***-****

Relationship: Manager at Honda

Current Position / Title: Manager at Honda

Years Known: 15

Name: Danny Combs

Phone: Work 502-***-****

Home 502-***-****

Relationship: Fellow Supervisor, Toyota

Current Position / Title: Manager, Arvin Meritor, Inc

Years Known: 15

Name: Barry Simpson

Phone: Work 502-***-****

Home 502-***-****

Relationship: Co Worker, Peer

Current Position / Title: Welding Process Improvement Coordinator at Toyota

Years Known: 20+

Name: Bill Botts

Phone: Work 502-***-****

Home 502-***-****

Relationship: Fellow Supervisor Toyota, Quality Coord. ToyoLex

Current Position / Title: Manager Ford Kentucky Truck Plant

Years Known: 15

Personal References

Name: Mr. Norman D. Christie

200 West Broadway

Campbellsville, Kentucky 42718

Phone: 270-***-****

Occupation: Real Estate Appraiser

Name: Mr. Elmer George

105 W. Main Street

Lebanon, Kentucky 40033

Phone: 270-***-****

Occupation: Attorney

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