Resume of Gary Haynes

*** ******* ****** **** *****: (internet): 678-***-****

Moore, SC 29369 Email: acwak7@r.postjobfree.com

PROFESSIONAL EXPERIENCE

dlhBowles (previously DLH Industries)

Nov 2014 – Jun 2016

Bristol, TN / Matamoros, MX

Plant Quality Manager - Southern

Company produces hoses for the automotive and non-automotive industry. Territory responsibilities included the assembly and extrusion operations in Bristol, TN and the assembly operations in Matamoros, MX. I had 1 supervisor and 3 - 4 quality inspectors reporting to me at each facility.

Major project was to transfer assembly fixtures from the Bristol facility to the Matamoros facility and document the transfer with capacity and capability data in required customer format.

Plant manager and I, along with the corporate management representative, were responsible for assuring that the TS-16949 quality system documentation and procedures were adequate to meet audit criteria. I was involved in numerous customer audits in both facilities.

After DLH merger with Bowles, decision was made to close the Bristol facility in June, 2016. Since my responsibilities would be significantly different than those that I was hired for, I received a separation notice due to the moving of the jobs out of the country.

Hutchinson Sealing Systems

May 2013 – Nov 2014

Church Hill, TN

Plant Quality Manager

Manufactured weather strips for Ford, GM and Chrysler.

Worked closely with the customer to define defect of weather strips. The weather strip commodity has transformed from a functional part to a class A surface (exterior). This shift in the weather strip commodity had caused a lag in the quality systems meeting the expectations of the customer. Major project was to close the gap without overpromising capabilities (assuring economic feasibility).

Worked with internal and external national and international customers on provide problem resolution on issues. Worked internally to reduce scrap and rework, showing a reduction in quality costs year over year.

Supervised 3 quality engineers, 1 administrative assistant, and 10 quality auditors. Responsible for monthly, quarterly, and annual corporate quality reporting for plant.

Dixien, LLC

Feb 2012 – Jan 2013

Warner Robins, GA

Quality Manager

Company produces injection molded plastic parts for assembly to automotive tier 1 facilities. Hired to aid in making the transition from outdoor power equipment to automotive as smooth as possible.

Instrumental in working with customers in the pre-production sampling of parts. Set up of specifications for new product utilizing APQP.

Responsible for the management of the TS-16949 quality program and was the management representative for all communications concerning the standard.

April 2010 – October 2011

Thomson Plastics, Inc.

Thomson, GA

Quality Engineer

Custom Injection Molding

Assigned key customer accounts to handle quality issues and to guide facility in corrective actions to assure problems did not reoccur. During this period, management at two of the main customers shifted to begin implementation of quality improvement efforts to drastically improve the customer perceived quality. The effect was in essence that product that was shipped last month was no longer acceptable. Quality standards changed with no notification.

From October 2010 until March 2011, I acted as the main quality contact for the plant due to the departure of the quality manager and the other quality engineer.

Responsible for reporting of all customer complaints and PPM data, as well as tracking corrective actions for all customer issues.

Out of the 500+ part numbers manufactured by the facility, I have updated more than 200 of the control plans, FMEAs, Flow Diagrams, work instructions, and inspection audit forms to address corrective and preventative actions taken.

Over the last 18 months, I have submitted over 50 PPAP packages to 3 different customer with no packages rejected.

Several packages required communicating statistical capability information to customer engineering personnel to support print changes allowing the successful submission of PPAP.

Participated in one 5S plant event which included 5 machines (1 relocated and area completely reorganized to include MRB area and new aisles for forklift traffic).

All areas were set up with “a place for everything” and an overall 12% productivity gain was achieved due to the new layout and flow.

Worked closely with approximately 8 suppliers on a regular basis in continuous improvement efforts. This encompassed most of our plastics suppliers, as well as our major hardware supplier (nuts, bolts, and miscellaneous fasteners).

Worked with several suppliers (over the 18 months at TPI) as incoming quality issues were identified and needed resolution.

The overall supply base was approximately 50 suppliers. I worked with approximately 60% of the supply base over the time I was at TPI.

August 2007 – April 2010

Helping In His Name Ministries – Community Food Bank

Stockbridge, GA

Warehouse Director

I was hired to direct all facets of logistics of getting food from donated source to a floor location in a form that it could be easily distributed.

The job entailed driving a box truck, a refrigerated box truck, a forklift (inside and outside), and utilizing a pallet jack to position items within the warehouse. When hired, the ministry had just moved to a new location and was working on plans to be able to help more families in the county.

During the time that I was there, we boosted families serviced from 32 families per day to over 60 families per day (with a peak of 90+ families at times). This included the logistics of routine pickups from food sources and assuring that there were adequate resources on site to assimilate the product into the warehouse.

The position also entailed the pickup, drop off, and scheduling of duties of three to four county inmates daily to aid in keeping the movement of food flowing through the warehouse in a FIFO system.

Responsible in supervising volunteers to help with the sorting and moving materials in the warehouse area.

Used 5S methodologies to begin an implementation of visual inventory management system. This system improved adherence to FIFO and decreased overall spoilage within the facility.

April 1995 – January 2007

St. Louis, MO, Griffin,GA, Piedras Negras, Mexico, Atlanta, GA

Cooper Standard Automotive

Automotive supplier extruded/ molded rubber products

Quality Engineer, QS 9000 Coordinator, Quality Manager, Corporate Quality Engineer, Customer Service Engineer (Atlanta area).

Began career with Cooper Standard as on-site quality engineer at Chrysler minivan plant in St. Louis,MO.

Responsible for daily reporting of quality issues to aid in preventing formal complaints of parts from the customer.

Promoted to QS-9000 coordinator within one year to certify plant to a QS9000 audit within a 9 month window. We achieved certification on our first try with no major non-compliances and only 2 minor non-compliances.

During this period, the quality manager left the facility and I was promoted to quality manager. I was responsible for corporate monthly reporting of PPM and COQ data

As part of the management team, I was instrumental in reducing COQ by over 40% in less than 30 months. As quality manager, I was the focal contact on all customer quality issues and determined actions required to address any quality concerns.

Supervised 3 quality engineers, a lab manager and inspection supervisors, with 16 hourly reports. With the improvement made over three years, the facility became eligible for the Chrysler Gold Pentastar Award by reducing our plant PPM from 234 to 49.

Approved all PPAP submissions forwarded to the customer through our quality engineers, including the technical reviews of the PFMEA and control plans. I taught SPC, problem solving, and QS9000 quality system classes to the facility.

Transferred to divisional quality engineering group and spent five years as the Atlanta Area Customer Service Engineer working on-site at the Hapeville Ford Assembly Plant, the GM Doraville Assembly Plant, and the Lincoln, AL Honda Assembly Plant; Cooper Standard had 7 manufacturing facilities shipping product to these plants.

Supported the plants by reviewing problem solving 8Ds and also worked closely with Ford Resident engineers in supporting plant DMAIC efforts and focusing CSA facilities to aid in reducing any negative inputs into Ford’s warranty data.

Worked with customer resident engineers assigned to drivetrain, water leak, internal comfort, and road noise focus areas.

Participated in 5S events in 2 different facilities. During this period, I also served as interim quality manager at the company's Piedras Negras plant in Mexico. This position ended due the closing of the Atlanta assembly plants in 2006 and 2007.

1993 – 1995

Washington, MO and St. Louis, MO

The Quality Continuum

Quality Consulting and Training

Owner

Provided training for companies requiring specialized training within the company. Types of training included statistical process control, FMEA's, industrial problem solving, and ISO 9000.

1987 – 1993

Berger, MO, Wabash, IN, Marion, IN

Bailey Corporation / GenCorp Automotive

Automotive Supplier of Extruded Rubber Products

Quality Manager, Divisional Quality Engineer

Started with the Bailey Corporation as the Quality Manager of the Berger, MO facility.

Worked closely with the management team to integrate all programs that were related to product quality and process improvement.

Implemented a Gainsharing program which relied heavily on quality and productivity reporting to compute payouts each month.

The programs results included significant reduction in plant-wide scrap, operators empowered to shut down operations when parts were not running correctly, plant-wide communication meetings weekly where the operators in each work cell reported out on their performance, and several of the work cells becoming self-directed whereby they scheduled their work and ordered materials through the internal KANBAN system.

The job of the quality manager was to communicate as effectively as possible ANY quality issue throughout the organization.

Utilizing an SPC program that was integrated and used by all functions of the company.

Each process and department was rated on a red, yellow, green rating system and the report was used in weekly communication meetings to management what improvement efforts were being introduced to address any red items (containment, customer print changes (Cpk’s less than 1.0)), or yellow items (continuous improvement items (Cpk’s greater than 1.0 but less than 1.33)).

Responsible for all PPAP submissions of new product to the customer. Engineering and the quality manager participated in APQP reviews on all new product to develop a PFMEA to address any critical customer items. The extrusion facilities of Bailey Corp. were purchased by GenCorp Automotive and the management team was changed.

Moved into divisional quality position where I supported supplier development for one year.

Dispatched to suppliers that had incoming quality issues and spent time at their facilities to improve processes and use capability qualification to resubmit PPAP data to document the improvements made to the system. I also signed off on the PPAP packages when they were submitted. This position was transitioned to a corporate QE position floating throughout the company as short-term quality related assignments were required.

Coordinated short-term assignments including interim quality manager in facilities, statistical and problem solving training, and special assignments as directed by the plant managers.

Completed a Lead Assessor of Quality Management training program which allowed me to apply for RAB Certified Lead Assessor status, but the company directives changed and I was unable to complete the required audit hours.

1985 – 1987

Clarke Pulley

Outdoor Power Equipment component manufacturer

Quality Manager

Facility's first quality manager. The management team integrated closure of the northern facility in Ohio without any increase in customer issues. The plant output (parts shipped) tripled in a period of 4 months.

1982 – 1985

Spun Steel Corporation

Automotive supplier of engine pulleys

Quality Technician / Quality Circle Facilitator

1978 – 1982

Diversified Products

Manufacturer of exercise equipment

Plant-wide Quality Inspector

Education and Training

August 1977 – July 1981

Auburn Univerity, Auburn, AL

Graduated with B.S. In Business Administration

Major: Industrial Management

Training

Passed courses in Statistical Process Control and Industrial Problem Solving and completed train the trainer classes in each curriculum.

Achieved Six Sigma Green Belt status with Cooper Standard, and also was an ASQ CQE. I was unable to complete recertification due to the fact that I was on assignment out of the country.

With GenCorp Automotive, passed the Lead Assessor training for Quality Systems (would have been able to complete RAB auditor requirements if job position had not changed).

Other classes: Lean Manufacturing, Quality Function Deployment, Microsoft Office, Team Oriented Problem Solving, completed Cooper Standard internal Green Belt Six Sigma training.

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