Manager Quality

Frank A. Duke, III CQE

* ******** ****** *****: 864-***-****

Columbia, SC 29229 ****.*****@*****.***

Profile

Certified Quality Engineer, Project Manager, Engineering Manager and Operations Manager, with a history of experience in Lean Manufacturing and Continuous Improvement. Diverse background spans production of rubber, plastics, electronics, polyurethane, leather, vinyl, and metals for the automotive and binding, pneumatics, oil and fuel filtration, sheet metal stamping slitting/coating, and welding and fabrication industries.

.

Career History

Quality Director/Manager Engineering Manager Operations Production Applications Manager Project Management Profit/Loss Responsibility Budget Preparation Project/Risk Management Problem Solving Team Leadership Motivation Employee Empowerment Training/Development Negotiations Safety Regulations Quality Systems Development/Implementation Standards Development/Implementation Product/Process Quality Assurance Continuous Improvement Lean Manufacturing Manufacturing Planning/Control Supply Chain Management Just In Time Delivery Total Quality Management Six Sigma/6S/8D Principles Structured Problem Solving Develop Inspection techniques/Procedures Statistical Process Control Taguichi Methods

Professional Experience

Porters Fabrication, Sumter SC Jan 2016- Current

Quality and Engineering Manager

Responsible for supplier, manufacturing Process and product Quality

Initiated 6S program, Fast response 8D problem solving

Negotiated drawing updates with the customer for PPAP submissions.

Coordinated/Managed new product launches for on time delivery.

Troubleshoot forming, laser cutting issues on light to plate steel.

Standardized the welding process to reduce processing time of units from 5 days down to 5 hours

Interface with customer to clarify customer needs, improve product to Meet needs and strengthen customer relations

CSI Steel, Columbia, SC 2014 – Dec 2015

Production Applications Manager/ Quality Engineer

Responsible for supplier, manufacturing and product quality

Initiated 6S program, Fast response 8D problem solving, improved customer relations.

Improved throughput of blanking line by 35%

Negotiated drawing updates with the customer for PPAP submissions.

Restored the use of PPAP documents as a tool for monitoring the progress of the quality system.

Hengst Automotive of North America, Camden, SC 2010 – 2014

Director of Quality Senior Project Launch Manager

Responsible for North America manufacturing and product quality. (New product launch quality, supplier quality, plant quality, customer quality issues). Managed 5 direct and 5 indirect reports.

Developed timelines and plans for the launch of new projects including implementation of SAP system in 4 months.

Decreased PPM from 35000 to 49, quality issues reduced from a high of 25/yr to currently 2/year in 2012. This contributed to the improved on-time delivery from 60% to 99% over this same time period.

Developed and managed multiple project launches and model changes, coordinating facility industrialization, purchasing, operations, engineering, and finance.

Reduced scrap from 3.5% to 0.86% by sales volume.

Improved Supplier Quality issues to the plant. (Casting issues, Sensors, Injection molded Parts)

Earned 2012 GM & 2013 Daimler supplier of the year

Frank A. Duke, III CQE Page 2

2 AM Group, Spartanburg, SC 2009 - 2010

Director of Quality and Manufacturing Technologies

Responsible for Corporate Quality to include collecting, analyzing, and reporting quality and productivity metrics.

Managed 8 direct and 53 indirect reports.

Developed growth strategies for manufacturing and automation/integration arm of 2AM Group.

Coordinated with HR, Logistics, Management, and Responsive Services branch of 2AM Group.

Audited and conducted root cause analysis, implemented methods to ensured compliance with

TS16949 and ISO 9000 AS9100 requirements and maintain ISO 9001 Certification.

Draexlmaier Automotive of America, Duncan, SC 2007 -2008

Plant Quality Manager

Responsible for the overall manufacturing quality of automotive interiors (New product launch quality, supplier quality, plant quality, customer quality issues).

Reduced the number of open customer complaints from 130 to less than 10 each month.

Improved the recovery of chargebacks to suppliers by $1.9M.

Introduced laser scanning technology which saved $138K while boosting capability and capacity.

Achieved 50% department headcount while maximizing efficiency and increasing the quality acceptance rate.

Led team that reduced PPMs from 800 to 282, exceeding corporate PPM reduction targets. (2 consecutive years)

Restored the use of PPAP documents as a tool for monitoring the progress of the quality system.

Accountable for P&L responsibility and prepared budgets for the department.

Recticel North America, Fountain Inn, SC 2005 - 2007

Operations Quality Manager

Responsible for the overall manufacturing quality of automotive interiors. (New product launch quality, supplier quality, plant quality, customer quality issues).

Managed Quality Operations for manufacturer of polyurethane interior trim for BMW and large-scale trucking companies.

Guided a team that surpassed corporate PPM reduction targets for two consecutive years, slashing PPM from 3,500 to less than 500, while outperforming the automotive group (ten units) in quality and productivity.

Utilized indicators to drive process improvement and support continuous improvement to a scrap rate of less than 1.5%. Cut average parts inspection time from 20 minutes per part to 5 minutes per part.

Reduced raw material usage by 28% by working with the supplier to provide a more stable product.

Plastic Omnium, Anderson, SC 2002-2005

Plant Quality Manager/Paint Operation Quality Engineer/Injection Quality Engineer

Managed quality of plastic components for automotive, medical, and waste management industries. (New product launch quality, supplier quality, plant quality, customer quality issues).

Reduced paint operations PPM to BMW from 3,500 to 90 while maintaining a scrap rate of less than 3%.

Achieved 0 PPM and 0 customer issues to multiple GM facilities for 18 consecutive months.

Designed and implemented quality and feedback loops to into the injection, paint, and assembly process for three plants across the US that included four direct ship customers.

Managed launch quality/standards development for new products in pre-production and production phases.

Designed a living catalog (shared with sister plants in Europe) to track and minimize color shifts over time.

Served as acting Plant Manager and Production Manager for injection operations in their absence.

Worked with paint suppliers to improve end product results. Removed the need to tint paint in house.

Worked with injection molding suppliers to improve and reduce variation in the process.

Frank A. Duke, III CQE Page 3

Sagem Inc., Greenville, SC 2000-2002

Senior Quality Engineer

Responsible for all Quality issues for manufacturer of fuel management systems for the automotive industry. (New product launch quality, supplier quality, plant quality, customer quality issues). Supervised 3 direct and seven 7 indirect reports.

Cut "D" injector scrap from 27% to 3% while decreasing overall supplier scrap by 45%.

Transformed $800K/month loss to $200K/month profit in 9 months on line volume by improving material specifications and working closely with Suppliers’ quality and management staff.

Improved Supplier machining process sequence to provide burr free machined fuel injector bodies.

Improved EDM machining process and Laser welding process to reduce process waste.

Toyota Gosei Missouri Corp., Georgetown, KY 1998-2000

Resident Quality Engineer Manager

Served as the primary engineering, quality, and logistics representative at Toyota Motor Manufacturing Kentucky, Johnson Controls, and Trim Masters in the manufacture of plastic and rubber parts for Toyota, GM, Ford, BMW, Dodge, Mitsubishi, Honda, and Isuzu. Supervised 4 direct and 36 indirect reports.

Addressed all quality, packaging, and shipping issues for over 3.2M parts shipped monthly.

Reduced scrap by 1,000 pieces/month to less than 99 pieces/month at shipping levels of 2.5M parts/month.

Created $300K savings in expedited shipment and travel costs 6 month period.

Played a key role in elevating Toyota Gosei Missouri Corp. to Toyota's "Most Favored Vendor" status by improving product quality and customer trust.

Education, Training, and Certifications

Project Management Professional Certificate University of South Carolina

Master of Science and Bachelor of Science Degrees in Quality Assurance Almeda University

Associates Pre International Commerce Oakland Community College

TS16949 Lead Auditor and TS16949 Internal Auditor Certifications, Excel Partnership Inc.

Certified Quality Engineer/Senior Member, American Society for Quality

Design of Experiments Greenville Technical College/Buck Mickel Center

Six Sigma/6S/8D Principles, LifeStar Training Company

Computer Skills including Microsoft Word, Excel, PowerPoint, Access, Visio, and Project

Contact this candidate