Quality Sales

*** ***** *****

Tuscumbia, Alabama *****

Cell Phone 256-***-****

E-mail: **********@***.***

Anthony S. Westfall

Objective

I’m seeking a professional career in a plant management role where my skills and knowledge will enhance the current operations and where there is room for growth within the company.

Professional

Summary

Professional

Experience

Multi-functional roles and experience in plant programs, materials, manufacturing, quality and engineering management. Launch new programs, plant start-ups, manage tooling, fixtures requirements, vehicle systems integration, production planning, scheduling, research and development, continuous improvement, lean manufacturing. Extensive knowledge of automotive & industrial materials and components, incoming supplier quality, quality engineer, assembly line and production management and shipping. Additional work in sales, marketing and product distribution management.

November 2014 – Present - North American Lighting, Muscle Shoals, Al

Plant Program Manager

Primary responsibilities are to manage new vehicle launches at assembly plant. Direct assembly plants cross functional management teams to successfully launch new vehicle front & rear lighting. Meet KPI’s for plants budgetary requirements. Meet capital expenditure requirements for equipment, tooling, capacity, floor space, direct/indirect human resources, and corporate cost savings initiatives. Schedule plant resources and provide regular project and financial reviews to corporate management.

July 2013- October 2014 - Glass Door Solutions, LLC, Elkton,KY

Materials Manager – New Plant & Facilities Start Up

Primary assignment to develop materials and facilities for group of owners to manufacture commercial refrigeration doors, shelving and frames sold for commercial walk in coolers for grocery, convenience, and multiple OEM accounts.

Set-up fishbowl software materials procurement system for materials ordering & tracking system, accounting control of expenses.

Develop all suppliers for facilities, components for the manufacture of doors & frames, carriers for inbound & customer deliveries.

Facilitate components change coordination with engineering associates, suppliers, and plant

Develop plants production equipment, production lines, materials storage, process flow, all plant requirements to produce and meet customer demand.

Set up safety procedures & safety facility for plant associates.

Company was sold as directed by owners for profit & continued operations for growth for new owner’s management team.

March 2013 - June 2013 Ford Motor Company(LAP)-Louisville, Kentucky

PVT(Plant Vehicle Team) Engineer-Ford C520 Escape

Recruited to join the Ford Louisville PVT Management team based on high level of experience in manufacturing environment metrics to be part of the 16 engineers responsible to reduce warranty claims and increase customer satisfaction through Ford’s BSAQ (Best Single Quality Actions) projects system on the global Ford C520/C489 programs. Forecasted LAP annual sales 389,000 vehicles/ $28,000 average sales per unit.

Primary responsibility is C520 Escape/ C489 Lincoln interior quality on the vehicle (coded V74) meeting dealer/customer satisfaction metrics. Including daily production quality issues.

Daily interaction with customers/dealers/service networks to review warranty claims and survey’s from customers. Claims evaluated lead to action plans to resolve current production issues and future model years engineering changes to satisfy customer requirements.

Responsible for supplier’s components quality and delivery, engineering changes, new model year changeovers, daily production quality.

Interface daily with global PVT teams in Spain (Valencia), China (Cha-Ching), and Russia (EU) to meet customer satisfaction globally on the programs which is produced in 4 countries. Engineering & quality initiates and changes carried over to all regions vehicles.

2010 - 2013 Webasto Roof Systems, Inc. Lexington, Kentucky

Plant Program Manager – Ford Programs

Plant program manager in engineering department for exterior commodity roof systems at Ford Oakville assembly plant in Ontario Canada. Direct program responsibility for $60 million annual sales for Ford 387(Edge) and Ford 472(Lincoln) panoramic moveable roof systems.

Manage the Lexington facilities two program assembly lines internal metrics for safety, quality, productivity, maintenance, and materials.

Manage service parts requirements.

Manage warranty requirements & metrics to reduce field issues with Ford team at Oakville assembly plant.

Manage engineering & cost reduction requirements. Regular interval Kaizen events, VA/VE exercises, corporate initiatives for materials savings. For 2012 reduced components/module assembly cost for $652,000 annual savings through life of program.

Present plant & customer metrics at weekly staff meetings, customer monthly visits at Lexington, externally at Ford Oakville assembly plant, and Ford Dearborn headquarters.

Integrate lessons learned on current to new programs at monthly reviews with advanced engineering development teams from Michigan, China, Mexico, and Germany.

Manage daily issues with Webasto on site representatives at Ford Oakville assembly plant and warranty field representative in Dearborn, Michigan to resolve dealer reported warranty issues globally.

2006-2010 – International Automotive Components (Previously Lear Corporation) Madisonville, Kentucky

Launch Engineering Manager

Plant program manager in engineering department for interiors unit, primarily headliners & blow molded products. Coordinate communication daily 24/7 via conference calls with plants, corporate teams, suppliers, and customer teams. Current facility is a union plant with numerous other customer union assembly plants.

Responsible for the quality requirements for the new launches including quality documentation, quality audits and inspections, scrap reduction and warranty issues.

Manage press & lamination lines to manufacture fiberglass reinforced composite construction. New core foam composite for new and existing programs. X61F to have this new box pour type composite construction.

Resolution of vehicle systems interface of mating components for design intent fit and finishes to meet the customers design expectations. Resolve complex air bag and safety deployment systems to align with multiple parts designs and functional interactions. Meet customer demands for complete satisfaction of products.

Manage engineering requirements for new programs and multiple parts RFQ/ECN changes for current products as required out through 2012 model years. Assist in future materials marketing proposals of future vehicles.

Manage monthly requirements for program management (Prolink) corporate metrics including APR’s, Plant Budgets, Scheduling, Launch/Production Roadmaps, Equipment Requirements, Supplier Requirements, and all Customer Launch Support Activities. Present metrics at monthly staff meetings.

Manage new program launches and all launch related requirements to customers at GM-Wentsville Assembly Plant, Woodbridge GM Parts Sequencing, Nissan-Smyrna Assembly, Nissan-Canton Assembly, and Miscellaneous service contract orders for numerous customer ship sites.

Manage & coordinate inventories, shipments, and purchase orders for new programs. Schedule pre-inventory meetings with staff to review inventory requirements for launch and production.

Train & Coordinate customer launch representatives (SQE’s) at all assembly plants.

Achievements

Successful launch 2008 GMT 610 Cargo-Passenger Van Headliners, successful launch of the 2010 model changeover. $13 million annual sales. Note that many vans are used overseas in the gulf coast countries for commercial and government use for cargo, ambulatory, and some military uses.

Successful launch D42A Nissan Altima headliners model changeover at Nissan Smyrna Assembly plant. $6 million annual sales.

Initiate new programs work-cell layout requirements, plant floor plans, train operators, operator instructions(SOP’s), work cell safety instructions(SOP’s), TAC boards, Program boards

Current launch engineer for Nissan X61F, first ever Cargo-Passenger Van at Canton, Mississippi - $48 million annual sales to IAC. Includes headliners & pass through door panel components at IAC Madisonville- $7.5 million annual sales.

Current launch engineer for Nissan X11C, Headliner Substrates off Lamination Line to Supply IAC Toluca Plant - $3 million annual sales .

Coordinator for supply base integration for increased revenue within IAC Madisonville and other IAC interiors plant sites. Approximately $13 million plants wide savings.

Completed Dupont’s industry standard (STOP) safety training, complete weekly safety production work cell Dupont (STOP) audits as required. Complete weekly Quality Layered Process Audits as required.

2005 – 2006 – DBM Technologies(Sold to Plastech then to Johnson Controls) Owensboro, Kentucky

Quality Engineering Manager

Manage quality & engineering staff for 2 blow molding plants. Both plants are union.

Modernized quality systems that where outdated with electronic and hard documentation to meet QS/ISO9000/14000 requirements. Prepared new documentation for production floor, added production boards, implement new procedures, work with maintenance on updated PM’s, lead plant cross functional meetings for audit preparations & schedule & coordinate ISO audits, train quality associates.

Manage engineering requirements for new programs and RFQ/ECN changes for current products as required.

Manage monthly MOR requirements for corporate metrics for quality ippm’s, External ppm’s, Quality Roadmaps, Costs Of Quality, and TS16949 audit requirements. Present metrics at monthly staff meetings.

Manage audit requirements with process maps for TS, customer specific requirements, and corporate system requirements to meet TS, ISO, and Environmental protocols. Schedule and coordinate surveillance audits.

Manage new program launches and PPAP requirements to customers. Customers include TMMK, TMMI, TG Missouri, Delphi, TBDN, Ford, Daimler Chrysler, and GM. Miscellaneous service contract orders for numerous customer ship sites.

Manage calibration requirements for gage fixtures, lab equipment, measuring devices, shipping scales, and maintaining manuals and data base for all equipment.

Manage customer corrective action requirements for sorting, sort companies, and customer corrective action responses as required.

Manage & coordinate quarterly inventories for plant # 1. Schedule pre-inventory meetings with staff to review inventory requirements, set up teams, review procedures for completing and taking inventory.

Coordinate customer service representatives at all assembly plants.

Achievements

Lowered internal/external ppm’s by 33%, lowest in company history.

Upgraded both plants standards for work-cells with new training manuals, operator instructions, work-cell layouts, operator training requirements, and gage fixture instructions.

Successful launch coordination for Toyota Camry at TMMK and pre-launch for 100,000 annual volume hybrids at Subaru-Lafayette plant. Toyota squam system requirements.

Successful launch coordination for Daimler Chrysler Cobalt (PM Program), Jeep Compass (MK Program), and Dodge Caliber (JS Program). New programs requiring new molds, tooling, gauge fixtures and production process for assembly of riveted assemblies.

Successful pre-launch of Toyota Tundra (180L) program for new assembly plant in San Antonio Texas. Set up system requirements for materials, production, and quality for this program. Pre-launch documentation and engineering requirements completed for this program.

Successful pre-launch of Ford Escape (U377) Program at Ford. Meetings with Ford STA, Ford engineers, pre-launch documentation and engineering requirements completed.

Completed process layered audit matrix with PIC group for implementation at both plants to meet Daimler Chrysler and GM requirements.

2004 – 2005 Lear Corporation Madisonville, Kentucky

Senior Quality Engineer

Incoming supplier quality for all components for parts as supplied directly to Lear and the OEM. Approve PPAP and all necessary quality TS16949 requirements.

Responsible for quality of parts and components as supplied directly to the OEM. Direct contact for quality concerns.

Coordinate customer and supplier visits, customer quality requirements, reports for OEE data base and roadmaps, track and coordinate reductions in PPM’s, quality surveys, audits, assembly line quality, engineering changes, RFQ’s, ECN,s, deliverables, issue quality alerts, root cause analysis, coordinate cross functional roadmap teams for internal quality and customer issues.

Coordinate outsourcing requirements as necessary for cost reductions to meet VA/VE requirements and plant layout for additional business.

Directly responsible for Nissan and Ford headliners, blow molded interior components, and numerous pass through components supplied directly to the OEM. Weekly visits to the OEM’s to coordinate engineering changes, respond to quality issues, and coordinate new model changes with program launches in 05, 06, and 07 model years.

Successful launch for 2006 Nissan Maxima Headliner

Successful launch for 2006 Ford U251 Explorer/Mountaineer Cargo Management System

Successful launch for 2006 Ford Fusion CD338 Seatbacks

Current training in Plexus ISO/TS16949 and completed Lear’s onsite TS Audit with Entela in October. Additional training in Core Tools for FMEA, MSA, SPC, APQP, LQTS, GD&T, Program Management, Roadmap & OEE Data Bases. Quality systems updates for production and corporate requirements.

Professional Experience

1993 – 2004 PolyOne Engineered Films Winchester, Virginia

(Formerly O’Sullivan Corporation-Leading Interior Supplier For 47 Years)

Automotive Programs Manager

Directs program tasks involving quality systems, production, communication, documentation, planning, and supplier compliance of automotive products for established manufacturer to the automotive industry. Skilled in instrument panels, door panels, multiple interior components and manufacturing processes for these parts. Technical expertise in compounds, foams, adhesives, coatings, TPO, PVC’s, tooling, and all manufacturing parameters from raw material suppliers.

Automotive Program Launch Achievements:

Ford DN-101 Ford Taurus Program - $12 Million

Cost save [width-.3%, 2-up-1.5% & die cut blanks .9%]

Honda Accord & Civic Instrument Panel Programs - $4 Million

Cost save [adhesive reduction-.5%, process reduction-1%]

Nissan Altima IP Program, Kantus–Kansei, Japan - $2 Million

Cost save [grain development-1.5%]

Delphi GMX 220/310 Instrument Panel programs - $5 Million

Cost save [blank size consolidation-2.7%]

Ficosa N. American Toyota & Nissan Sun Visor Programs - $2 Million

Cost save [thickness and width reduction-1.7%]

Ford SN95 Mustang FN145 Lincoln MP & DP Programs - $4 Million

Cost save [coating change-1.3%]

GM P90 Pontiac Instrument and Door Panel Programs - $4 Million

Cost save [thickness reduction-2%]

M-Tek North American-Nissan Door Panel Program-$1 Million

Cost save [adhesive change-2%]

2004 GM Cadillac XLR Evoq & GMX 245 Corvette-$2 Million

Cost save [formulation change-11%]

Current Program Launches:

2004 Nissan UL Quest & Frontier IP Programs - $3 Million

2004 GMX 381 Epsilon DP Program - $4 Million

2004 Nissan Altima IP Program - $4 Million

2006 Honda Civic DP - $2.7 Million

Account Management Responsibilities:

Collins & Aikman Honda of America

Delphi Mexico Ficosa Mexico

Ford – Nissan Toyota

General Motors Daimler Chrysler

Project Integration

Coordination of quality systems and quality associates

Production planning; deliveries, inventory control, performance reviews (EDI releases)

Quality and production crisis resolution, on call 24/7

Research and development test requirements and new product development coordination

International & Domestic partnership relations

Project Communication

Customer and suppliers visits

VA/VE cost reductions

Sales and marketing exchange

Domestic/international supplier quality and material requirements

Management

Cross functional plant and product team leader

Customer issues and quality meetings

Communication through on-site customer visits

Pre-production and trials coordinator

Continuous improvement, lean, mistake proofing exercises (DOE, PSO’s)

APQP (advanced production quality planning - 23 quality elements)

In process quality documentation compliance

Plant quality audits (QS/ISO) and standardized procedures

Beginning TS16949 industry quality standards

Contract review

Decision reviews for verification & DFMEA

Subcontractor (supplier) APQP compliance

Facilities, Grain tooling, Gauge R&R Studies

Control plans and builds (pre-launch/production)

Engineering drawings & R/D specifications (DVP&R)

Manufacturing process flow

Operation process instructions

Packaging specification requirements

Capabilities studies (CPK, SPM, PPM’s)

Color harmony/functional approvals

Part submission warrants and production orders

Safety

Management

Maintain safe work practices - Dupont STOP Training- Always Use PPE’s

1984-1993 Vyline Corporation Long Beach, California (O’Sullivan Corporation West Coast Operation)

Sales & Marketing Manager

Direct sales, marketing and distribution of products on West Coast, Pacific Northwest, West, Southwest and Western Canada territories.

Marketing Analysis

Sales & profitability reports

Customer quotations

Create and distribute brochures & sales aids

Logistic analysis

Schedule of incoming shipments from international and domestic facilities

Inventory systems control

Quality control and customer service requirements

Carrier routing and scheduling

Coordination of products from multiple production facilities internationally and domestic

Manage warehouse and inside sales associates

Schedule travel as required for customer visits

Account Management Responsibilities:

Peterbilt (heavy truck instrument panel) – Portland, Oregon

Toyota (Nummi instrument panel) – Freemont, California

Lockheed (L1011 cockpit instrument panel) – Los Angeles, California

Microsoft (software packaging) – Seattle, Washington

IBM (software packaging) – San Jose, California

Hewlett Packard (software packaging) – Santa Clara, California

Compaq (software packaging) – San Jose, California

1979-1984 O’Sullivan Corporation Winchester, Virginia

Plant Supervisor

Injection molding supervisor

27 machines from 300 to 1500 ton

Automotive interior components

Manage 60 operators and mold technicians

Mold Technician

Troubleshoot and resolve process issues

Mold set ups

Machine Operator

Machine and assembly operator

Lab Technician

Laboratory physical testing

Compounding and color matching

Inventory Control

Physical inventory

Education - Achievements

1979-1984 Shepherd University (Liberal Arts University) Shepherdstown, West Virginia.

B. S. Degree Biology .D

Citizenship award.

Pilots’ license.

Coast Guard Seamanship Certificate.

Tennessee Walking Horse Owner and Trainers Pick Of The Year.

Quality Core Tools Certificates.

Dupont Safety Training.

Plant Manager-Supervisor & Leadership Training

Ford Systems World Engineering Release System (WERS) Training & Certificate.

Management Systems Training – Skillsoft (84 Hrs) - Certificates in Finance, Directs Reports Management, Lean Concepts, Sex Harassment, Lead By Enabling, Accountability, Time Management, Goals & Goal Setting, Constructive Criticism, Team Trust & Management, Problem Solving & Process Management Tools, Communication Skills, Union Awareness, Rightful Employment Termination, Management Delegation.

Ford Motor Company corporate ethics training.

Ford Motor Company safety training

Ford Motor Company BSAQ(Best Single Quality Actions) system training.

Fishbowl software systems training

NAL Plex plant software systems training - proficient

NAL Product lifecycle management systems training - proficient

NAL Sensitivity–Respect For Employees training

NAL AS400 Materials-Inventory system-proficient

NAL Annual EMS-Environmental training

NAL Annual Forklift-Warehouse Safety Training

NAL Annual Safety Training

NAL Problem Solving Methods Training

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