Senior Quality Engineer Automotive/Medical
Resume:
JAMES M. BARNETT
Kalamazoo, Michigan 49001
**********@*****.***
Summary of Qualifications:
Seventeen years of automotive and medical part manufacturing in quality control. I am experienced in dealing with a fast-paced environment where deadlines must be met. Expertise includes APQP, control plans, flow diagrams, process FMEAs, scrap reduction, PPAP, poke-yoke, problem resolution, customer interaction, internal audits, layered process audits and instruction simplification. I have worked in management at Tier 1 and Tier 2 facilities and have trained and audited as a TS Auditor. I have worked mostly in metal machining, stamping, green sand foundry, welding, and assembly, but have recently worked in plastic injection and printed foils for injected parts. I am data driven, and am an analytical decision maker with excellent problem-solving skills. I have been the point person in TS-16949, and QS-9000 audits and I am fluent in all basic computer programs (Excel, Word, PowerPoint, and AutoCAD) as well as GD&T.
WORK EXPERIENCE
Eimo Technologies May 2016 to December 2016 Senior Quality Engineer Vicksburg, MI
-Working in both automotive and commercial programs.
-Quality Engineer for Chrysler, Panasonic, Diebold, Neaton, and several other new programs just launching
-Worked with set-up personnel in understanding the proper settings to set the machines
-Number of issues at Panasonic have fallen by more than 50 percent – no product has been rejected after training on machine set-up in June
-Worked up SPC spreadsheets that plot automatically saving a large amount of time plotting and graphing data for Whirlpool/Maytag and Avon
-In process of updating information for launch of 42 parts by Diebold (verify and correct paperwork), develop part specific instructions, work with operators and set-up personnel
JVIS USA January 2016 – May 2016
Quality Engineer Benton Harbor, MI
-Handled the Dodge Ram program (upper glove box doors, map pockets, etc.).
-Worked with Yanfeng Interiors and Chrysler in determining root cause of badges falling off, excessive noise from glove box mechanism, and sticky latch.
-Limited liability to JVIS by examining the issues which had been chronic at varying times over the last seven years.
-Provided Quality Engineering in a facility that had been manned with only one Quality Engineer for over a year
Cosma Castings July 2015 – September 2015 Contract Quality Engineer Battle Creek, MI
-Ran the Melt Department
-Increased quality and machinability of product to internal customer
-Assisted in obtaining critical equipment for proper melt operations
-Reviewed critical data and put it in place easy to follow summaries and charts
-Decreased number of metal spills from one per week to none in three weeks
-Increased compliance with standardized work instructions
-Improved training of new employees in handling molten metal
Stryker Corporation – Integrated Manufacturing June 2010 to December 2012
Supplier Development Engineer, Senior Quality Assurance Engineer, Kalamazoo, MI and Quality Lab Supervisor
Medical Equipment Manufacturer
- Responsible for investigating quality issues and submitting all data through Stryker’s on-line problem resolution software.
- Worked hand-in-hand with the suppliers for both machined components and raw material coming into the plant to address quality issues and to improve their quality performance.
- Managed an eight person quality assurance laboratory to make sure parts that were being inspected were inspected properly and in a timely fashion.
- Streamlined and improved the accuracy of the month end data collection and posting of graphs reflecting the data.
- Worked on improving the efficiencies of the quality procedures with a goal to cut down on costs (excessive overtime, non-value added operations, etc.).
Magna/Cosma Structural Systems April 2006 to March 2009
Assistant Quality Manager – Interim Quality Manager Williamsburg, IA
Stamping Facility with Weld and Assembly facility
- Responsible for all product in the plant (Chrysler, GM, Mazda, and Ford – Tier 2 to Nissan) and Infinia Solar program
- Re-establishing outdated Quality System to TS16949 and introducing Lean Manufacturing
- Revamp entire Layered Process Audits on all production lines
- Point person on all internal auditing, developing weld department and weld technicians, and quality supervisors and quality technicians (responsible for 17 individuals)
- Main responsibility is dealing with the production floor improvements and handling Chrysler – Belvidere Assembly Plant
Tenneco August 2005 to April 2006
Chrysler Value Stream Quality Engineer Marshall, MI
Exhaust System Manufacturer and Assembly facility
- Responsible for all Chrysler product in the plant (Dodge Ram / Dakota)
- Completed 2006 launch of product and 2007 Mid-Bed, 2008, 2009 product changes
- Initiated DPM (defects per million) procedures for Chrysler production line
- Re-established Layered Process Audits on the Chrysler, as well as updated all documentation to the finished product cells and muffler line for the 2006 model year
- Developed monthly scrap tracking program by defect with monthly paretos for corporate review
- Point person for all customer concerns with contacts at Chrysler - St. Louis North Assembly Plant and Warren Truck Assembly
Teleflex Automotive February 2005 to August 2005
Quality Engineer Kendallville, MI and Lyons, OH
Brake and Accelerator Assembly facility
- Responsible for three quality engineers, and support staff
- Closed all open issues at Kendallville (30+) and transferred to Lyons in June and directed the closure of 45+ additional open issues
- Was the quality point person in the value added step of producing wipers for electronic throttle control internally instead of purchasing. Had received approval by Nissan and GM when I left
- Implemented extensive poke-yokes (hard and soft) for production line (welding and assembly)
- Developed photo extensive labeling and packaging guidelines for use at the line and in shipping in order to centralize data on labeling and packaging (our primary customer issue)
- Created a more robust Quality Alert system to improve communication throughout the facility
- Improved customer relations as the point person for all customer concerns. Handled Chrysler - St. Louis North, Warren, Milwaukee, Saltillo, and Austria, Ford – Kentucky Truck, Kansas City, Norfolk, Louisville Assembly, Dearborn Truck, and Atlanta, and GM – Bowling Green, Toluca, Lordstown, Oshawa 1 and 2, Wentzville, Warren, and Martinsburg, Nissan – Canton, and Smyrna
Flex-N-Gate April 2004 to November 2004
Quality Engineer and Quality Manager Battle Creek, MI Stamping and Assembly facility
- Responsible for staff of thirteen on three shifts – engineers, auditors, technicians, document control, and support staff
- Reviewed all up-dated prints and verified new production processes
- Verified and validated all error-proofing on assembly units
- Completing open issues from previous TS-16949 audit
- Took necessary steps in removing 18 products from controlled shipping (Level 1 and 2)
- Worked closely with our customers and our company’s customer representatives on handling quality concerns and problem resolutions of the 60+ plants we supplied (Ford, GM, Nissan)
J.L. French June 2002 to November 2003
Quality Engineer Glasgow, KY Die Cast and Machining facility.
- Reviewed print changes and adapted all paperwork accordingly
- Developed necessary paperwork for all new production parts – including the numbered prints, Process FMEAs, Control Plans, Work Instructions, Flow Charts, Gaging Instructions, and Operator Instructions
- Assisted in developing new in-process and final gaging
- Verified gaging and tooling
- Developed PPAPs for changes in dies and new product launches (approximately 70 per year)
- Addressed all corrective actions (customer, supplier, and internal)
- Tested and re-designed (if applicable) check fixtures used on the production floor
- Collected and reported monthly data for GM and Ford
- Developed systems to monitor and address areas of internal issues and supplied all data for management review
-Worked closely with customers on addressing customer concerns both in-house and at the customer facilities
Harvard Industries March 1999 to June 2002
Senior Quality Engineer, Quality Supervisor, Customer Service Albion, MI
Representative
Nodular and Malleable Iron Foundry
- Reviewed new prints and print changes with production engineers
- Developed necessary paperwork for all product changes
- Assisted in developing new gaging per print
- Verified all hand gages
- Developed data reporting program that tracked the top 12 defects by each product line for upper management and floor personnel
- Developed tracking and reporting program for various programs (including, tool room, core department, finishing, and personnel)
- Developed spreadsheets that calculated Gage R&R, CPs, and CPKs with minimal amount of input
- Acted as the point person for all corrective actions (customer, supplier, and internal)
- Took on role as Quality Supervisor due to retirement, but kept all engineering responsibilities
- Managed staff of five quality auditors on three shifts
- Substituted for technicians on the floor whenever necessary
- Customer contact for several Michigan customers and all of the Canadian and Ohio customers
- Performed site visits to customers on a monthly basis to address accumulations, foundry and machining issues
CDM International April 1998 - March 1999
Quality Manager Jackson, MI Screw Machine facility
- Responsible for all customer interactions with the plant
- Reviewed new prints and print changes
- Developed necessary paperwork from prints, launched all new parts
- Designed and verified all gages and tooling for manufacturing operations
- Developed procedures for QS-9000 system
- Developed spreadsheets to streamline quality activities and eliminate redundancies
- Managed quality technicians on the floor
- Revised and simplified SPC data collection system
Miller Industrial Products January 1997 - February 1998
Quality Engineer Jackson, MI Bullard Machine facility
- Collected computer data from machine centers
- Translated data from gage downloads into reportable format
- Developed Process FMEAs, Control Plans, Work Instructions, and Flow Charts from numbered prints
- Assisted in developing procedures for QS-9000 system
- Developed spreadsheet for tracking and reporting quality and production information
Envirologic Technologies/R.W. Mercer August 1989 - December 1996
Field Geologist to UST Coordinator, Senior Geologist, Kalamazoo and Jackson, MI Environmental Department Head.
- Established bidding program for environmental site assessments and UST removals
- Performed field work including soil sampling, installing and developing monitoring wells, measuring water tables, etc.
- Developed reports for DNR, DEM, EPA in Michigan, Ohio, Indiana, Kentucky, and Illinois
- Coordinated projects with field crews
- Worked closely with clients on all projects – including working with MUSTFA (Michigan UST reimbursement fund)
- Established liquid industrial and hazardous waste disposal department which consisted of a vacuum truck and a set of covered roll-offs
- Assisted clients in waste characterization, sampling, and disposal
- Drafted all site maps and site plans – trained others in AutoCAD
- Strong geologic background including six years consulting (1983-1989), exploring, and developing oil and gas ventures in Kentucky, Texas, Alabama, Michigan, and Illinois
EDUCATIONAL EXPERIENCE:
Western Michigan University August 1980 – March 1983
Masters of Science in Geology Kalamazoo, MI
Thesis: “Depositional Rate of the A-1 Evaporite of the Michigan Basin as Determined by
Micrometeorite Analysis”)
University of Iowa August 1975 – August 1980
Bachelors of Science in Geology Iowa City, IA Two years in Mechanical Engineering - Material Science
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