Anthony M. Conley Sr. ASQ CQE

**** **** **

Louisville, KY 40299

502-***-**** acx2bf@r.postjobfree.com

Senior Quality Leader

Aerospace/Defense/Consumer Good/Medical

I am positioned to add value to your organization. I have over 20 years of leadership in quality systems, lean, six sigma and continuous improvement implementations. Additionally, I have significant training, project management and quality planning experience.

My experience in quality systems management of ISO based standards spans 9001, AS9001, 13485, 14001 and TS16949. My familiarity and knowledge of these systems has allowed me to lead the quality function in multiple industries with successful preparation and sustainability of ISO based quality management systems. I have advance computer skills, data mining and reporting experience with ERP/MRP systems and SPC software.

I have very strong customer communication and advocacy skills as well as significant regulatory compliance experience ( FAA, FDA, NSA).I am well versed in quality tools such as; 5 WHY, 7 and 8D RCCA processes as well as applying APQP, PFMEA, DFMEA, PPAP and other quality methodologies to manufacturing problem solving. My hands on work experience spans sheet metal fabrication and assembly; complex electronic equipment manufacture and assembly, appliance manufacturing and design including design of injection molded parts, printed circuit board manufacture and assembly, NC Machining and CMM inspection planning, small and medium motor manufacture, automotive device manufacture, metal stamping and forming processes (including roll forming), various chemical processes, forgings and castings, plastic injection molding, electronics assemblies, PWA and PWB.

PROFESSIONAL EXPERIENCE

BAE Platforms & Services

INDUSTRIES: DEFENSE AND ELECTRONICS

PROCESSES: SHEET METAL FORMING; MACHINING; PAINTING AND OTHER FINISHING PROCESSES; HEAT TREATING;

REGULATORY STANDARDS/SYSTEMS: US REGULATORY COMPLIANCE TO DFARS; ISO 9001

2014- present

Supplier QUality Manager

Provide quality assurance remedies in support of customer and supply chain objectives and purchased materials .. Manger the supplier quality activites of 8 supplier quality engineers and maintain customer liaison.

Qcc Consultants

INDUSTRIES: CONSUMER PRODUCTS; AEROSPACE; APPLIANCES; FOOD PROCESSING EQUIPMENT; DEFENSE AND ELECTRONICS; AUTOMOTIVE

PROCESSES: SHEET METAL FORMING; MACHINING; PAINTING AND OTHER FINISHING PROCESSES; ELECTRONICS –PWA & PWB ASSEMBLY AND MANUFACTURE; HEAT TREATING; SUPER PLASTIC FORMING OF TITANIUM, METAL BONDING; HYDRAULIC CYLINDERS AND LINES/FITTINGS; ALUMINUM PERMANENT MOLD AND SAND CASTINGS; ALUMINUM AND ZINC DIE CASTINGS AND MANY OTHERS.

REGULATORY STANDARDS/SYSTEMS: MULTIPLE ISO BASED SYSTEMS INCLUDING MEDICAL, SPACE, AVIATION, DEFENSE, AUTOMOTIVE, NADCAP AND ENVIRONMENTAL.

2013- 2014

Principle Consultant

Provide services to multiple industries for processes improvement. Those services span multiple ISO quality system auditing and client preparation for certification; Plant training in 8D and Problem solving; including PFMEA; Lean and 8 waste training.

Key Electronics, Jeffersonville, IN

Industry: Printed Circuit Board Assembly

Processes: SMT; Hand Solder; AOI; PWA box build; Wave Solder; PWA Testing; Conformal Coating; Wire harness

Regulatory Standards/Systems: ISO 9001; ISO 13485; AS9100: UL approval.

2012- 2013

Director of Quality

Responsible for leading the quality journey towards AS9100, QMS improvement, and a world class quality environment in the printed circuit board industry in Kentuckian. Have successfully completed and obtained AS9100 certification. Obtained green belt status as part of a robust lean management team environment.

Avcorp Industries, Inc, Delta, BC

Industry: Aerospace

Processes: Sheet metal fabrication; Hydro-forming; CNC machining; assembly of hydro-lines and fittings; Heat treating;

Conversion coating; Paint; riveting; Cleanroom composite assembly;

Regulatory Standards/Systems: AS9100; TC 561-(Canadian equivalent to FAA); NADCAP

2010 - 2012

Director of Quality

Reporting to the CEO, responsible for maintaining the quality management system (AS9100 C) and deployment of the quality function. Have responsibility for inspection, quality engineering, MRB activity, Laboratory testing, CMM, NDT and LPI certifications and inspections. Responsible for reviving Lean and continuous improvement of activities including event planning and employee Lean and 6S and RCCA training. Conducted Lean and RCCA training to 5 value stream teams for 2012 events in planning. Responsible for maintaining NADCAP special process certifications, Transport Canada compliance, as well as manage a staff of 54 hourly and professional quality assurance associates. Responsible for quality contract review and management of quality documents and quality system management using PLM system.

Masonite, NASHVILLE, TN

Industry: Construction

Processes: Fiberglass door fabrication; Foam injection; Machining;

Regulatory Standards/Systems: Wood and Construction ANSI

2009-2010

Plant Quality manager, Lean Site Champion

Reporting to the GM, responsible for establishing a quality management system and Lean Six Sigma site leadership. Completed yellow belt, green belt certification training and lean site champion training for belt project this year. Responsible for Continuous Improvement projects. Participated in 2 Kaizen events and led one.

Triumph Fabrications, Hot Springs, Arkansas

Industry: Aerospace

Processes: Sheet metal Fabrication & Assembly: Hydro-Press; Brake forming; Contour forming; Heat Treating;

Coatings; Painting: SPF; Roll Forming; Tube Bending; Machining;

Regulatory/Systems: AS9100; FAR Part 21; NADCAP 2006 - 2009

Director of Quality

Reported to the President of a 60 million dollar company with 380 associates. Four direct reports of quality engineering manager; inspection manager; Lab manager and document control administrator. Responsible for 39 inspection personnel and quality engineers. Company produces sheet metal aerospace parts for all major airframe companies. Monitored and performed inspection and testing of chemical milling process; prime and paint process; heat treating and hand forming; CNC 3 and 5 axis machine centers; Sheridan Gray stretch forming presses; Hydro forming utilizing one of only 4 globally produced 20,000 psi ABB presses; maintained Level 3 and 2 penetrant inspection programs. Lab performs micro polishing and some chemical alloy analysis. Lab is responsible for all chemical process monitoring including salt spray, tensile, hydrogen, calibration and clean room certification for adhesive bonding. Responsible for internal audit system to AS9100, NADCAP special process certifications for heat treating, chemical milling, titanium hot forming and super plastic forming, chemical coatings and material testing and monitoring.

Utilized Crystal reports to avail waste stream data and other related data throughout the organization. Accomplished in under one year from zero visibility of data to users.

Initiated lean/continuous improvement teams to address issues such as:

oSelf-inspection system to flow accountability and responsibility to the appropriate level. Created a manufacturing self-inspection procedure that is being implemented in conjunction with an employee empowerment program.

oDeveloped a quality manufacturing team to address historic silo management cultural issues.

oOrganized a quality engineering course based on the ASQ CQE primer and trained all quality engineers and some manufacturing engineers in the body of knowledge and applications for quality engineering activities.

oConstructed a team to evaluate revising manufacturing planning to simplify/utilize visual objects for communicating instruction.

Conducted RCCA training for operators, supervisors, quality engineers and manufacturing engineers.

Implemented an on-line nonconformance system in 4 weeks within first 3 months on the job.

Successfully led an AS9100 recertification from a critical shortcoming environment in the first 2 months on the job.

Smiths Aerospace Mechanical Systems, Yakima, WA

Industry: Aerospace/Aviation

Processes: CNC machining of large cylinders; gun drilling; hydraulic fluids testing and assembly into pistons; EDM

Regulatory/Systems: AS9100; FAR Part 21; NADCAP; ISO 14001

2004 - 2006

Director of Quality

Reported to the president of a 70 million dollar company with 280 associates. I maintained the AS9100, NADCAP, FAA repair station certifications and managed the quality engineering, calibration, inspection and customer quality interfaces for all major aircraft manufacturers. I had 3 direct reports to cover these functions and an administrative assistant for quality records. Primary products produced are actuators for landing gears and doors on commercial and military aircraft. I was also responsible for penetrant inspection with two level 2 NDT operators. Metallurgical testing was outsourced when required. Calibration and tool maintenance was performed in house. Heat treating and carburizing where also outsourced.

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Created and implemented key quality metrics reporting and automation using Access and Crystal Reports.

Implemented on line forms to eliminate current paper systems in use for non-conformances and FRACAS reporting using Omni-Form.

Created a waste reduction team to address scrap and cost of poor quality and improved turnaround time of the Preliminary Review (MRB) decision from 3 months to 20 days in 2 months.

Reduced obsolete scrap and waste by eliminating backlogs of unusable material in MRB that was still being carried in inventory.

Armor Metal Group, Madison, IN

Industry: Military/commercial container fabrication

Processes: MIG/TIG/spot welding

Regulatory/Systems: MIL-STD-45208; QS9000

2003-2004

Corporate Director of Quality and Safety

Reported to the president and COO of a 150 million dollar company with 230 associates. I had four direct reports and 3 plants quality managers. My primary location in Madison made military containers from heavy gauge steel and plate. Containers where MIG and TIG welded. I maintained the operator weld certification program. I was responsible for safety at this plant as well as the two Cincinnati plants. One plant machined large machine base casting for machine manufacturing companies. Hardness and metallurgical testing where performed to customer requirement. X-ray and penetrant inspection of large forgings and castings where outsourced. I also was responsible for the ISO certification at the 3-plant operations and for establishing a corporate safety program and policies to OSHA requirements.

Created and trained management and union employee in root cause analysis and 5S awareness.

Implemented internal audit system for successful measurement of quality systems improvements and compliance.

Implemented a continuous improvement program to lead variability reduction team efforts.

Trained management employees in quality system requirements for MIL-I-45208. Led a successful certification to this standard in 3 months in a union environment.

Received General Motors training to TS 16949 standard for implementation.

Implemented an on-line nonconformance reporting system and defect classification system utilizing Omni-Form. System outputs will identify continuous improvement projects for root cause analysis by workforce teams.

Roll Forming Corporation, Shelbyville, KY,

Industry: Aerospace/Commercial extrusions and structures

Processes: ROLL FORMING; BRAKE PRESSES; Coatings; Painting: Tube Bending; Machining;

Regulatory/Systems: AS9100; QS-9000; NADCAP

1998-2003

Quality Assurance Manager

Reported to VP engineering of a 200 million dollar company with 300 associates. Assured product quality of roll formed structural aerospace parts and assemblies. I had 3 direct reports in the aerospace division of this company with about 8 million dollar sales annually. I had 1 quality engineer and 2 inspectors. We manufactured airframe extrusions to customer specifications. Parts where made from aluminum sheet heat treated and formed in the W condition.

Led and consulted continuous improvement teams and provided corporate training for 5 Why and Root Cause Analysis and 8D corrective action.

Conducted Six Sigma Training to over 50 new employees.

Wrote and conducted all training presentations for heat treat and other projects in the division.

Designed and implemented corporate electronic internal reject system- reduced forms reproduction by 50% and provided the corporate system for identifying six sigma/continuous improvement projects.

Led AS9100 quality system certification effort, which positioned company for an additional 7 million dollars in sales as a qualified aerospace supplier.

Led a NADCAP special process audit with all findings submitted and accepted within allotted time. Certification led to qualifying company as a special processor and eligible for 2 –3 million dollars in additional sales.

Spearheaded continuous improvement project that automated in line stencil process, thereby eliminating operator errors with an annual savings of $20,000.

Participated in value stream mapping for key finished part assembly area leading to a 25% reduction per hour in labor charges.

Performed gap analysis for implementation of TS 16949.

Sumitomo Sitix Silicon, Inc. Cincinnati, Ohio

Industry: Semiconductor

Processes: NPN, PNP, Epitaxial layer growth, silicon slicing, growing, machining, Class100 and 10,000 cleanroom

Regulatory/Systems: QS9000; QSR; ISO 9001, ISO 140**-****-****

Quality Systems Manager

Reported to the VP quality and managed the Quality System function for this 70 million dollar company with a 500 associates. Maintained all ISO and QS-9000 and Motorola QSR Six Sigma Quality systems and process procedures as well as 3rd party surveillance coordination. I performed process capability/benchmarking studies/reports, customer audit interfacing, quality data reporting and analysis and SPC training. Managed the activities of 2 documentation specialists and a systems administration/programming person. Company manufactured silicon ingot for device manufacturers such as Intel, Samsung, Siemens and AMD in a clean room environment.

Led QS 9000 implementation certification effort and provided training to management and hourly employees and provided SPC training for engineering and maintenance staff and facilitated DOE training using Statgraphics software.

Implemented an on line paperless ISO compliant documentation system and managed procurement of hardware and software.

Performed GAP analysis and pre-audit survey for ISO 14001.

Reduced cycle time for specification approval by 70% using electronic system.

Responsible for nine successful (without a hold point) ISO 9001:1994 surveillance audits, 2 Motorola QSR assessments and triennial recertification audit.

Capital outlays of $40,000 ROI of 1.2 years with net annual savings of 2500 hours implementation of paperless document control system.

Westinghouse Electric Corporation- Baltimore, MD 1979 -1995

Xetron Corporation, Cincinnati, Ohio 1990 to 1995

A wholly owned subsidiary of Westinghouse Electric Corporation/Northrup Grumman.

Industry: Aerospace

Processes: Sheet metal Fabrication & Assembly: Hydro-Press; Brake forming; Contour forming; Heat Treating;

Coatings; Painting: Roll Forming; Tube Bending; Machining; Electronic PWA/PWB assembly and Test; rotor core blanking

Regulatory/Systems: AS9100; FAA Part 21; NADCAP; MIL-Q-9858

Quality Engineering/Systems Manager 1990-1995

Reported to the director of quality of this subsidiary with 70 million dollar sales and 280 associates. Had 3 direct reports for Quality Systems and Engineering, calibration and an inspection supervisor. I also had responsibility for the maintenance of all Quality procedures, updates and audits for compliance and adequacy to MIL-Q-9858. Processes included soldering and pick and place component machines; module testing and electronic PWA/PWB assembly and software design and testing. Responsible for ISO 9000 and Boeing A9000/D19000 quality system implementation planning, data reporting, SPC training and procedures. Managed the Calibration activity with oversight for MIL-STD-45662A compliance and ISO compliance. Responsible for the Procurement Quality Engineering activity, Vendor Quality Rating System and supplier reports.

Wrote Quality Plans for major military hardware programs and proposals including manpower planning and resource allocation as well as program quality plans for hardware and software bids and proposals. Planned proposals in excess of $6million dollars.

Provided training for DFMEAs, SPC, ISO and Boeing D1900 quality systems.

Provided quality engineering support for the manufacture of PWB, PWA, wave solder, stitch weld, robotic component placement, surface mount, hand soldering and high voltage soldering, and MW module tuning/testing.

Wrote and presented quality program plans for various emerging programs and new technology bids.

Responsible for the Quality Assurance department capital appropriations budget and managed department budget for 5 engineers and 2 technicians.

Sold off deliverable hardware to government including reliability and test data in excess of $30 million dollars.

Improved the corporate supplier rating at Xetron by managing the calibration compliance to MIL-STD-45662A non-compliance. Reject rate from seven to zero percent in one year with savings of $65000.

Planned and implemented Boeing Company D1-9000 quality system implementation and key characteristic program at Xetron. Planned and implemented an on-line quality procedure system that is accessible on LAN network. Eliminated hard copy quality procedures and reduced errors of the audit trail.

At Xetron, planned capital equipment expenditures that resulted in 47% reduction of subcontract calibration costs by bringing services in house and purchasing calibration standards.

Managed 3 shifts CMM inspection department of 6 technicians at the Defense Division, with efforts saving major program delivery penalties of $64,000 per month.

Implemented cost of quality tracking system at Defense Division that identified major cost improvement opportunities in the high voltage inductor coating and heat-treat departments as well as assembly areas.

Defense and Electronics Division, Baltimore, MD.

Senior Quality Engineer 1987 to 1990

Reported to the quality engineering manager at this 4.2 billion dollar company of 25,000 associates. No direct reports but had significant customer interface for buy-off of major ground and airborne systems. This company produces all assemblies and product on site. Performed various DOD program Quality duties. I had significant foreign customer interface for sell off of major radar systems to customer representatives. Performed audits, process improvement projects, manpower budget, cost proposals and estimates. Significant project management responsibility for overall program quality plan implementation for airborne and ground radar systems.

Supervisor Quality Control/Inspection 1985 to 1987

Supervised mechanical inspection department of 20 inspectors for welding, machining, plating, painting, PWA assembly, and subassembly areas. Provided training in the use of coordinate measuring machines and other touch probe instruments and managed inspection operation with 6 CMM programmers.

Purchased 5 touch probe 2 axis measurement systems and trained and performed Gage R&R for 45 inspection and hourly shop personnel.

Capital expenditure of $50,000 and savings in labor and material due to measurement error of $98,000.

Managed inspection coverage and workflow for PWA/PWB assembly; paint and finishing; TIG welding; LSA assemblies; final customer system sell off

Quality Engineer 1983 to 1985

Performed planning and quality analysis of mechanical processes in a model shop/prototype environment. Had responsibility for Quality audits for compliance to MIL-Q-9858, MIL-C-1520, and MIL-STD-454 processes. Performed problem analysis of various processes including heat-treating of aluminum and steel machined and cast parts and assemblies. Applied SPC to laser-positioning machining process for waveguides.

Quality Engineer Small Motor Division at Lima, Ohio 1979 to 1983

Quality Engineer for Small Motor Division manufacturing fractional HP motors up to HP. Performed quality analyses (DOE) and process improvement projects. Processes included heat treatment of sintered bearings and motor shafts. Developed division quality procedures; assigned as field service engineer with responsibility for the Midwest area with major customers being Maytag, Kenmore,Amana,White-Westinghouse,ColdSpot,D&M. Administered warranty program as field service engineer. set up repair shops, dispositioned customer line returns, trouble shooting of motor applications and usage. represented South American territory and made regular customer visits to Caracas, Venezuela. Saved $150,000 in warranty line returns. Led zero defect team investigation of deformed shafts for furnace motors using DOE. Resulted in $$75,000 savings. Designed first of its kind rotor core TIR and RO automatic gage. Reduced inspection time from 10 minutes to 30 seconds. Led zero defects team effort to reduce shorts at surge by improving winding tool maintenance and a DOE of varnish process that resulted in change of viscosity and lower temperature cure.

Hobart Corporation, Troy, Ohio

Industry: Appliance and Commercial Food Equipment

Processes: Sheet metal Fabrication & Assembly: Hydro-Press; Brake forming; Contour forming; Heat Treating;

Coatings; Painting:Roll Forming; Tube Bending; Machining;

Regulatory/Systems: NSF; UL; Aluminum casting Association

1977 to 1979

Quality Engineer

Assigned as Procurement Quality Engineer for casting supplier quality.Coordinated cost/design improvement of aluminum permanent mold, sand, and die-castings in the Commercial Food Equipment Division. Problem solved for various casting processes including; heat treating of permanent mold castings; burnishing; heat treating of drive shafts and food processing equipment parts; sand casting mold design and yield improvements.

Reduced aluminum casting defects for porosity by assisting in the redesign of major food equipment castings. Annual savings of over $5.00 per unit were realized.

Provided significant supplier quality support to aluminum sand, cast iron green sand, permanent mold, and die cast parts suppliers. Performed all surveillance audits and troubleshooting at suppliers.

Lead the casting defect continuous improvement team and came up with process improvements to casting finishes through burnishing and approval by NSF of process as method to repair porosity.

Assigned to VP of engineering for special projects that included casting redesigns; R&D ion sputter deposition of aluminum for porosity coverage; replacement of low yield castings for porosity with machined or stamped parts.

General Electric Corporation, Louisville, Kentucky

Industry: Appliance

Processes: Sheet metal Fabrication & Assembly:injection molding; wire coating; brake forming; blanking;

Coatings; Painting: Machining;

Regulatory/Systems: UL; ANSI;

1970 to 1977

Product Designer

Responsible for the design of various mechanical systems for the Home Laundry and Dishwasher departments. Performed design layouts and tolerance studies, built prototypes and engineering test models. Designed injection molded parts such as the pot scrubber tub; escutcheon chrome plated trim for backsplashes; seal ring retainers for dryers; Co-submitted 3 patent disclosures; Set up wiring harness boards for new plant in Mexico; Worked on advanced dryer, washer, and dishwasher designs in R & D department.

Additional capabilities & training:

Effective Presentation Courses

Procurement/ Materials Management

Training/Development

Budget Planning

Regulatory Compliance

Staff Management

Problem Solving/ SPC trainer

Change Agent

Team Leadership/ Motivation

Decision Making course

Lean/6 Sigma Facilitator/6S

Significant project management experience

TRAINING AND CERTIFICATIONS

Relevant Training and Certification programs:

Quality Engineering School (Westinghouse),

Value Engineering (Canada)

Root Cause Analysis and 8D

Quality Improvement Process Training/TQM

Six Sigma team implementation

Government Contractor Management Evaluator Training, Auditing

Safety Policy for Management

D1 9000 Implementation

IRQA ISO 9000 Lead Assessor Training (Lloyd’s)

Supervisory Communications Seminar

AS9100: 2000 QMS Implementation ( PRI)

QS-9000 Review, Statgraphics

Supervisory Management Training Development Course (University of Cincinnati)

Defect Detection for Aluminum Castings

Query Management Facility (QMF)

JD Edwards World Writer A73

MS Access programming

AIAG QS-9000 Internal Auditing

Lean Manufacturing (Boeing)

JIT Training (RFC and Boeing)

Geometric tolerancing

ISO/TS 16949 training

NSF/FDA training for aluminum casting defect detection in food equipment

Fimilar with the CMMI process improvement model and the Cosby Maturity Matrix as a tool

COMPUTER SKILLS

Software Applications: Advanced skills with Microsoft MSOffice (MSWord, Access, MSPowerPoint, Excel, and Project); Expert Crystal Reports; OmniForm; SPC QA America, Statgraphics, other SPC packages. Skilled at data mining and reporting from Oracle and SQL ERP databases using Crystal Reports.

EDUCATION

University of Louisville, Louisville, KY 1977

Bachelor of Arts in Physics

Louisville Technical Institute, Louisville, KY 1970

Associates in Mechanical Engineering

PROFESSIONAL MEMBERSHIPS

ASQ member and Certified Quality Engineer since 1983, SAE member, AAQG member/ Supply Chain Management Handbook (SCMHB) contributor.

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