Quality Engineer Manager

EDUCATION

St. Lawrence College of Applied Arts and Technology, Kingston ON 1980

Electronics Engineering Technology (US Equivalent to BSEE by L.A. INS)

Touro University International, Cyprus CA 2009

Bachelor of Science in Business Administration

TECHNICAL SUMMARY

Six Sigma / Lean / Root Cause Analysis / Cycle Time Reduction / Shainin / SPC/ Team Building / Taguchi / Kaizen / Engineering Management / ISO 9000 / TS 16949 / JIT / Quality Training / PPAP / APQP / FMEA / 8D / Run at Rate / MSA / Control Plans / Flow Charts / TQM / AIAG / DOE

PROFESSIONAL SUMMARY

I am the technical side of Quality Engineering/Management and am hands on, on the floor

Use Six Sigma Black Belt, Taguchi and Shainin’s Statistical Engineering methods for problem solving

Helped multiple Fortune 500 companies such as Motorola, United Technologies, Control Data Corp., Chrysler Ford Motor Company, and General Motors to solve engineering, manufacturing and supplier quality issues

Set up and trained teams that reduced costs of manufacturing by over $100,000,000 and improved yields in production for automotive, rubber, computer hardware, wire, semiconductor, and electronic manufacturing companies

Years of experience in teaching managers and engineers how to apply statistical methods for analysis to solve engineering challenges, improve capability, reduce costs and control processes

PROFESSIONAL EXPERIENCE

Inalfa Roof Systems, Auburn Hills, MI 06/2014 – Present

Sr. Supplier Quality Engineer

Work on supplier quality issues for sustaining and new product launch. Conduct systems and process audits as required.

Yazaki N.A. Canton, MI 08/2012 – 06/2014

Quality Engineer

Working with Chrysler on warranty and plant related quality issues. Assisted in solving two customer related long term issues using Shainin Statistical Engineering and Six Sigma techniques which reduced warranty costs by 75%.

Kostal of American, Troy, MI 04/2011-07/2012

Quality Engineer

Working with Chrysler and Ford on warranty and plant related quality issues

Conduct testing and failure analysis on suspect parts both in the USA and Mexico

Conducted several Shainin DOE’s at our manufacturing site in Mexico to resolve issues on Chrysler products

From 2005 to 2011 worked for several contract houses on a variety of assignments which lasted from a few weeks to a few months. Contract houses I worked for were MSX, Aerotech, The Productivity Team, Gonzalez Staffing, The Technical Resource Group.

Valeo, Auburn Hills, MI

Resident Quality Engineer and Supplier Quality Engineer 01/2000-07/2005

Consulted with a number of suppliers on new product launches and sustained engineering of existing parts

Commodities covered were metal stampings, machined parts, insert and injection molded plastics as well as a electronic, electrical components and assemblies

Quality Systems (QS9000 based) and Process Audits were conducted as well as Run at Rates at supplier sites

Evaluated and approved PPAP submissions

Consulted with suppliers at their sites, completed root cause analysis when problems occurred and validated corrective actions

Taught statistics, SPC and problem-solving techniques related to the supply base

Conducted a control chart analysis when the Valeo Rio Bravo plant in Mexico had field failures on ignition switches. This was accomplished using Minitab on historical data which indicated that the process was out of control and incapable. Conducted a Taguchi Design of Experiment to optimize the process and eliminate weld failures with a savings of over $100K in scrap per year

Supported several new product launches at GM, Ford and Chrysler for a variety of platforms

Consulted on-site at Spring Hill, TN for 5 months during the Saturn Ion launch. All issues were addressed and closed prior to start of production resulting in a flawless launch

Determined the root cause of field failures and coordinated corrective actions with production, our design team, and Ford and Chrysler warranty centers

Superior Essex Group Quality Manager, (Six Sigma Black Belt), Fort Wayne, IN. 09/1997 – 04/1999

Addressed a number long-term quality issues that were impacting our customers as well as our profitability

A member of the copper improvement team I worked with the Concast Quality Manager and hourly workers in evaluating the process flow and capability. $8M per year per cost savings was identified.

Determined root cause of Near End Cross Talk (NEXT) at which was a long-term quality issue on LAN Cat 5 and LAN Cat 6 wires.

Responsible for ISO9000 certified quality system for the plant and corporate locations.

Taught statistical analysis, problem solving, SPC and how to use the Data Analysis Tool Pak of Excel to engineers and managers

A position was created by Superior Essex Senior Management so I could focus on problem solving, yield improvement and cost cutting provide there was a $500,000 in cost savings and no solution was evident.

Plant One in Fort Wayne had customer and scrap issues due to bubbles forming in resin insulation for heavy gauge transformer wire. I found variation in the copper wire dimensions at a mill between the widths of wire produced when the mill first started compared to wire that was drawn after the mill had been running for a few minutes. This caused insulation application to be thicker where the copper wire dimension was smaller causing bubbles to form during curing. Plant added thermal compensation to reduce variation, cutting field and in-house failures and saving $2M on one product line. I also participated and organized Kaizen events.

Goshen Rubber, Corporate SPC Manager, Goshen, IN 1993-1994

Plant One in Goshen IN. was losing money for a number of years due to yield loss. This was the numbers of parts per pound of rubber were never realized. Conducted a process flow analysis of the plant to identify the problem area then set up a team in manufacturing to conduct capability and multi-variant analyses

As a team member, identified that extrusion dies were source of production variation which were reworked so all the extrusion holes on the same die were all the same size. The dies were put on the PM schedule to prevent reoccurrence and computer based SPC was implemented to control the process. This resulted in $800K reduction in yield loss and $250K in scrap. The material savings from reduction of liquid nitrogen for cryogenic deflash, premium freight and labor were not calculated but the plant from 12% loss to 12% profit in six months

Bond Flex in Columbia City, IN. had been spending a large amount of money on destruct testing for the rubber to metal bonding process. Completed statistical analysis on the capability of the metal to rubber bonding process and greatly reduced the number of destruct tests required. This reduced the cost of testing by $100,000 per year.

Wimmer INC, Contracted to United Technologies Electronic Controls, IN 1990-1993

Sr. Quality Engineer and SPC Coordinator

Taught bi-weekly 20 hour classes on SPC, Statistics, Process Capability and Problem Solving Techniques classes to improve the knowledge of statistical methods and process control

The Converse IN. plant was losing money on appliance control boards and had numerous customer complaints

Worked with the operators to streamline the setup procedure to reduce cycle time and set up errors

Optimized the wave solder process to reduce the number of units in touch up and repair

Reduced the work in process, premium freight, late deliveriest and customer complaints

Improvements on the appliance line made $5M profit in six months and customer satisfaction was improved substantially

Additional Information:

I am an ASQ Certified Quality Engineer, Certified Six Sigma Black Belt, Certified Manager of Quality and Operational Excellence, Certified Quality Auditor and Certified Supplier Quality Professional

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