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Quality Manager

Jenison, Michigan, 49428, United States
95k +
October 06, 2016

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Thomas J. Sturm

**** ******** ***. **********, ** 49418 616-***-****

Proven leader, coach and mentor in the quality disciplines. Hands-on experience with Program Management, Toyota Production System, Continuous Improvement, 6-Sigma. Advanced Quality Planning, Lean Manufacturing, ISO-9000 and TS-16949. 20 yrs CQE, 10 yrs. CQA, 5 yrs. RAB 3rd Party Auditor, 6 Sigma Greenbelt.


Corporate Quality La Crosse, WI

Advanced Quality Planning Engineer

Develop the Trane Global APQ Process for New Product Introduction. Train and implement globally throughout the organization.


Faurecia Exhaust Division Toledo, OH

Corporate Quality Manager of New Program and Current Product Quality Aug 2006 – June 28, 2007

Manage the Program Quality Group to ensure product quality in design, development and launch of new programs.

Manage the production quality activities for implementation of the Faurecia Excellence System Quality objectives at all manufacturing locations.

48% improvement in FES Quality implementation

Developed and implemented enhanced APQP for all new product programs

Director of Quality Engineering Nov 2003 – Aug 2006

Multi-plant responsibility for planning, developing and implementing techniques for ensuring both product and organizational quality in new program APQP and current program customer satisfaction.

Achieved Global Best Customer PPM performance within Faurecia

Championed two 6-Sigma projects resulting a $500,000/yr cost reduction

Achieved TS-16949 Registration at all facilities

Achieved Ford Q-1 at two new Divisional sites

Implemented Faurecia Excellence System (FES) Quality objectives at eight sites – FES is based on the Toyota Production System

Faurecia Seating Division Troy, MI

Director, Program Systems Development and Program Manager May 2000 – Nov 2003

P&L responsibility for $70M/yr. Automotive Seating Track & Mechanisms program from design through launch. Responsibilities include engineering, sales, manufacturing, finance, purchasing and quality.

Developed Faurecia Seating Program Management System as part of Global Team

Achieved flawless, on-time, high-quality and profitable launch of new GM seating product

Collaborated and negotiated with customer resulting in achievement of corporate directed margin

Faurecia Exhaust Division Toledo, OH (formerly AP Automotive Exhaust, Inc.)

Director of Quality Engineering Apr 1999 – May 2000

Multi-plant responsibility for planning, developing and implementing techniques for ensuring product quality.

Facilitated implementation of APQP process development and implementation.

Provided hands-on, on-site launch direction and implementation assistance for new product launches.

Implemented 8D team oriented problem solving initiative throughout operating units


Structural Systems Division, Grand Rapids, MI

Quality Improvement Director 1999

Provided leadership, direction and implementation assistance in solving complex quality problems.

LEAR Chrysler Division, Rochester Hills, MI

Vice President of Quality 1997 – 1998

Multi-plant responsibility for APQP, current product quality, supplier quality, warranty, customer satisfaction and QS-9000 at facilities in U.S.A., Mexico, Canada, South America and Europe

• Developed and implemented an effective APQP system for new product development.

• Implemented warranty reduction program that resulted in a $2,000,000 savings in model year.

• Improved Customer Satisfaction Rating from 78% Needs Improvement to 85% Satisfaction rating in nine months.

• Expanded the implementation of the QS-9000 system from procedures to value-added application.

T. Sturm Page 2

QUALITY CONSULTANT, Rochester Hills, MI 1997

Independent ISO/QS-9000 auditor and quality improvement consultant to tier-one automotive suppliers.

Lean manufacturing / Toyota Production System implementation.

Non-value-added process analysis.

Quality training in SPC, Problem solving, QFD, ISO-9000, QS-9000, etc.

MAYFLOWER VEHICLE SYSTEMS, Farmington Hills, MI 1992 -1997

Vice President of Quality 1995 - 1997

Responsible for initiating, developing and implementing a QS-9000 based Quality Operating System throughout the three manufacturing facilities with $100 million sales. Management of the Supplier Quality Activity for the global supplier base. Led and directed Product Quality Engineering Activity. Customer liaison to ensure the adherence to requirements and measurement of customer satisfaction.

Achieved QS-9000 certification within nine months at the three manufacturing plants

Attained Q1 status at the Shadyside Stamping Plant

Managed the development and implementation of the Corporate Strategic Quality Plan

Championed a Kaizen implementation at the Norwalk Assembly Plant which led to a 45% reduction in plant inventory, reclaimed 20% of production floor space for future growth opportunities, and reduced the cost of nonconformance 29% through the identification and elimination of non-value added activities in the assembly process

Quality Director 1992 - 1995

Responsible for development and implementation of a corporate quality operating system to meet the requirements of the automotive OEMs and ISO-9000.

Achieved Third Party ISO-9002 Certification at all manufacturing plants within twelve months

Implemented the Ford QOS system throughout the organization

Assisted in the development of QS-9000 as a member of the AIAG TAG-Quality Team

Achieved yearly double-digit improvement in all quality indexes for three years running

Developed and implemented the corporate quality activity including the Quality Engineering activity for new programs and the Tool & Equipment Qualification Process for new tooling


Corporate Quality Manager 1989 - 1992

Multi-plant responsibility for the Lear automotive seating J-I-T plants, injection molded plastic components plant, seat interior trim cut & sew plants, and frame manufacturing plants in the U.S., Europe, Canada, and Mexico. Developed and implemented OEM required quality systems, new product planning APQP, supplier development, systems auditing, customer liaison and customer award attainment.

Attained the GM Mark of Excellence Award, Ford Q1 Award, and Mazda MVS Awards

Developed and implemented the Corporate Quality Operating System

Refined and implemented the internal quality compliance audit system

Participated in a multi-functional team in the Greenfield startup of plants in the U.S. and Europe


Director of Quality and Productivity Improvement 1988 - 1989

Responsible for day-to-day operation of the quality activity at all facilities.

• Implemented a continuous improvement process that resulted in increased productivity, profit, employee involvement, and customer satisfaction.

Developed and implemented employee kaizen teams

Assisted with the development and implementation of employee gain-sharing system.


C-P-C Operations Quality Group, Warren, MI

Senior Project Engineer 1985 - 1988

Quality support to GM Assembly Plants during pilot build and new vehicle launch. Provide quality improvement training, consulting and assistance with implementation of the GM Synchronous Manufacturing Techniques based on the Toyota Production System.

Trained, consulted and implemented the Synchronous Manufacturing Techniques at four assembly plants

Provided consulting and implementation assistance to the GM/UAW Quality Network during its initial inception as a member of the Immediate Action Team

Developed and implemented the department operations budget and business plan during the first year of C-P-C

Served as CPC Divisional coordinator for the GM Internal Customer Satisfaction Survey.

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General Motors Fisher Body - Group Quality, Warren, MI

Internal Quality Consultant and Trainer 1983 – 1985

Responsible for designing, developing and delivering training classes at the Fisher Body Quality Institute. Also required to provide consulting, training and implementation assistance to Fisher Body Plants and Key Suppliers for implementation of

the TQM Quality Improvement Process based on the disciplines of Deming, Juran and Crosby.

Developed training material and taught classes in SPC, Cost of Quality, Problem Solving, Team Dynamics, JIT, Strategic Planning, and TQM

Provided consulting, planning and training for successful implementation of the TQM Process at eight Fisher Body plants and three supplier locations.

Fisher Body Metal Stamping Plant, Grand Rapids, MI.

Supervisor - Layout and Match Check 1982 - 1983

Supervisor - Supplier Performance 1981 - 1982

Supervisor - Inspection 1976 - 1981

Supervisor - Pressed Metal 1974 - 1976

Supervisor - Metal Assembly 1972 - 1974

Hourly Production Worker 1969 - 1972


Masters of Science in Administration, Central Michigan University, Mt. Pleasant, MI 1986

Bachelor of Science in Business Administration, Aquinas College, Grand Rapids, MI 1979

Associate of Science in Business Management, Davenport College, Grand Rapids, MI 1975


Vietnam Era Veteran – Military Police – Honorable Discharge 1969 – 1971

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