David A. Fay

**** * ******** ***** • HOWELL, M I CHIGAN 4 8 843

PHONE: 248-***-****

ad32k3@r.postjobfree.com

PROFESSIONAL EXPERIENCE

TREMEC Corporation – Wixom, Michigan.

Metrology & Chemical Laboratory Manager 02/18/2018 to present Quality Engineering Manager 2018-Jan2019

• Recruited to build the Quality Department to support the confidential transmission build for the C8 Corvette for GM-Bowling Green KY.

• Joined the TREMEC Belgium Team for 2 months to learn the assembly and operational issue to establish criteria for Quality validation of at the time a prototype transmission that was moved up 1 year in its time to market delivery.

• Hired 4 Staff members to begin Plant Quality integration of IATF Standards and Metrology Laboratory setup of systems and infrastructure.

• Purchased & installed lab equipment to a ISO-17025 level. Overseeing the Lab construction and Quality Cap-Ex financials exceeding the 11month required operation status timetable, delivering in 9 months and 3 days while staying in budget. Achieved KPI Goal set by the TREMEC VP from MX.

• Built the Metrology Inspection Team with handpicked team members with diverse skills and backgrounds in Machining, Casting, Injection Molding and process operation-manufacturing skill sets. Emphasizing the protocol that one must understand the assembly before one and inspect the components.

• Created the (TDPG) TREMEC Developmental and Performance Goals protocol. Training and Mentoring were critical to a highly engaged family of Inspection and Engineering measurement specialists working to support the new assembly line that was being installed from Eagle.

• Administrating the buyoff process of the line in Benton Harbor was handled smoothly and worked through time delays with the vendor and reporting to TREMEC Corp QRO Mexico. Conducted MSA Studies with GM-Powertrain Quality management to establish the hurtles we would have upon line installation in the Wixom Facility.

Incoming Quality Manager 2019-Feb2020

• I was chosen by the Director of Corporate Quality to head the newly created department of Incoming Quality.

• Hired 8 Staff members with Incoming Inspection & Quality Engineering backgrounds, training in SAP and Production assembly hands on (Real World) engagement working on the TREMEC Production line. Supporting this protocol was working with the change Supplier Quality team from contractor to TREMEC direct staff.

• Managed this team reducing the DMR issues from 197 occurrences to 3 per month over a 12 month period.

• Created the Corrosion Management Policy for Vendor handling/packing and Internal handling/storage of all material for the Corporation. Saving 1.6M in lost time and decreasing the time for evaluation in the Chemical lab for cleanliness class level of 5 along with microscopic vision measurement.

• My staff’s performance KPI directly affected the 38% increased production FTQ.

• Created SAP coded algorithms for QA33 Quality release of batch identified material to speed dock movement of held material.

• Created the Gage Technician position to support the Wixom Plant tools requiring Calibration support. Using Gage-Trak the department passed 3 internal audits without being cited for non-conformances, promoted In-coming Quality team member to this position supporting the company code of ethics and engagement.

Commented [DF1]:

Metrology & Chemical Laboratory Manager Feb2020-Present

• Promoted to Metrology & Chemical Manager with my extensive Metrology and Engineering background.

• Position encompassed the Incoming Inspection Dept joining the Metrology Dept to have one Team to be the Technical Measurement Services Group for the TREMEC Corporation.

• Accessed current practices and staffs accountable support for ethical operations. Defined the changes and the protocol the team member were to follow for Communication, Data reporting and compliance with Traceability to the IATF Standards.

• Participated in retraining the Team on the measurement software’s used in the lab, defined the training certification to be followed and reviewed by our internal IATF certified auditors and the manufactures Senior programming staff. This change made a positive work environment platform to having a happy staff and even happier internal and external customer that receive data and communication through very clearly defined reporting formats using PowerPoint and video data sets.

• Creating the new Corporate Workflow System in Power Apps as SharePoint was phased out, this allows the customer to have 24hr access to their secured data documents traceable to the work order.

• Designed a new work location in the plant to bring together the Measurement and Chemical teams, presented the scenario to corporate for approval, coordinated commercial contractors, equipment riggers, equipment calibration manufactures and all while keeping the labs operational with a 2 day down time to make the moves. Having outside services ready and PO’s in place to support the plants needs during that time. Cost savings in the staff having less walk time and safety concerns with parts on carts and Hilo traffic was $165k. The costs for the complete project in total including staff time being engaged was $158K.

• I am the financially responsible Manager for all Quality Dept cost tracking, purchase requestion & PO approval. I dually support accounts receivable/payable for prompt payment to suppliers to the Quality Dept for cost savings negotiated during the quoting phase. This has saved to date $395K in spending allowing the Quality Dept Manger to show a metric of under budget for the past two years.

• TREMEC’s new Romulus Distribution center added a new support challenge as we now ship to TREMEC Wixom and GM-St. Catherine’s, our work order system was revised to support a Skip Lot process so the Labs could be sent material for inspection and certified material would be returned to the container it was removed from and shipped with documentation for the end user. This process requires engagement each day from the coordinators in the labs and MP&L staff @ the DC. GM was added to the document centers CWF for Canada’s access to the traceable documentation noted on the shipped materials per IATF Guidelines and the Contract with GM.

• I oversee the Chemical teams’ operations daily, giving guidance to the standards for best practices and safety adherences while handling volatile chemical and maneuvering parts in the Pall cabinet and inspection process for cleanliness and particulate data collection.

• My dept follows strict inventory of all equipment and consumables, chemicals are processed 1 time per week and evaluated from the usage excel documents from each cabinets main inventory. These process and protocols have been adopted by the QRO-MX & Belgium Operations as Company standards.

• The efforts of ethics, accountability and measurement and communication are noted by the teams and managers from the kuo-TREMEC Corporate companies is seen by the number of staff that visit the Wixom Quality dept to learn and be a part of the processes that have been set as the Standards by which the Company operates.

• I have the highest staff retention scale in the Plant, my staff have been promoted to other positions and 2 to Supervisory roles. This I believe is due to my mentoring, work ethics and care for developing a great work environment to grow talent in.

• I am part of the IATF Integration team, teaching other departments how IATF works, and how we can have it work for us. Working with the teams to write the Process and Procedures that support the work that each department is done and documented.

• In my position I have direct communication to GM on the C8 Corvette platform, I am the Customer Quality contact for deliverables to FORD Motor Company Flat Rock on the Shelby GT-500 transmission that TREMEC builds in QRO-MX. I also support DETROIT DIESEL Redford on all DD-12 transmission components sold from QRO-MX.

BNC – BRIGHTON NC MACHINE CORPORATION.

Director Quality Assurance & Compliance 04/14/2014 to present

• Joined BNC to support Kevin Alder – President, CEO and 4 other new to the company Directors in saving the company from a failed corporate system that included a poorly built and executed Quality policy. Early January 2014 the company had lost their FORD business & Q1. ISO-9001 certification and was in the final weeks of losing Detroit Diesel business due to not just certifications but non-conforming material being found at the customers build locations in the US and Europe. MTU-America / MTU-FN reduced their material content with BNC 75% leaving only simple casting brackets and manifolds.

• April 14th 2014: began rebuilding the QA Dept. with a Protocol Standards of Ethics, assigning the 9 staff members to a job responsibilities metric system of PDCA. Each member was trained to work as a team and participated in team Internal/External workshops (i.e. MMTC) and first responder medical emergency unit certification. On the 16th of April 2014 I escalated an emergency ISO audit with American Systems Registrar to define the gaps in the current policy, failing the audit was a known prior result to define the needs and actions for the Board of Directors and the customers that were exiting the business. Directing my Team to start anew and build a system to carry the company to a viable and profitable organization that it had once been. Working with the key mid-level management directors and manager from DDC, Ford, Caterpillar and MTU the new Director team moved aggressively to work in our specific skill sets.

• May 2014: New Quality Operating System approved and implemented. Training with all department managers and leaders and plant support personnel was aggressively undertaken, follow thru meeting on the progress was simultaneously ongoing with the customers building a positive belief that the business in jeopardy should not be removed with the efforts and a guarantee that BNC would regain our ISO certification by October 2014. Teamwork and support of the workforce @ BNC gave the company a return to a ISO certification in late June 2014.

• July 2014: Awarded new business from Caterpillar, FORD, Webasto and DDC. In part due to the training and execution of the systems and the belief we can do what was thought by many that our effort where in vain and we would fail. New business yielded a 8.7 million increase for 2014. Including a transfer program from a competitor supplier (MCI-Brighton) that went out of business with no warning to Caterpillar and MTU. BNC was able to react and meet the production needs due to the engagement of positive thinking and resilient teamwork we had brought and honestly believed in.

• August 2014: Training implemented for Advanced Quality System’s. Lead Auditor, Internal Systems Auditor, SPC & SharePoint Document Control. Core Tools with Yellow Belt training for Production, Operations leaders and Engineering staff. Focusing on the MRB system and the reduction of the monthly scrap that was over 780k in 2013. Town Hall quarterly meetings with all employees to build communication and strengthen the values for a successful operation that would be a completive manufacturer and making BNC a unique place to be employed at.

• July 2015: ISO/TS-16949 – ISO/9001-2005 Certification was awarded with the Advanced Quality planning training and systems installed and operational in all departments. Consecutive awards for 2016 & 2017

• August 2015: Ford Q1 – Service awards for R47F/EAOD Transmission Pump components and Assemblies, delivering FORD OEM quality certified product through the FORD Parts network for dealership/consumer use.

• Integrating a new Suppler Quality System and team to work directly with Customer Service and Purchasing. This group works directly with the suppliers to support the supplier/s needs were BNC material and or services will be in process. Supporting metrics for Management review and providing scorecard data and support actions as Supplier awards, PPM and 8D documentation transfer & Cost of Quality.

• Supporting a 2 and 3 shift operation of QA Staff and Production Leaders.

• Continuing a leading directive to maintain and excel each day to meet the expectations for the customer while providing stability for the employees and BNC.

• Supporting the Metrology Department in mentoring the team and programming the Hexagon 122010 DCC CMM with PC-DMIS 2016 online and offline with and without cad. Reverse engineering tooling and fixtures. Creating the electronic PPAP packages to meet the customers’ expectations.

• Chairing customer audits and visits to BNC and sharing the company’s vision of the future and how we will get there by the work done with our customers and our team at BNC. Customer communication is the greatest strength to a solid business environment.

• Being a key associate in the companies’ community support program of growing vegetables in joint operation with the Gleaners Food Bank association on the 5 acre farm on site. VRSI – VARIATION REDUCTION SOLUTIONS INC.

Facility/Quality Manager / Aerospace Process Control Lead Engineer 01/2010 to 04/2014

• Onsite Build Manager on the F-35 JOINT STRIKE FIGHTER Aircraft Build at Northrop Grumman-Palmdale and El Segundo, Ca. Working with MANTEC Engineering, Kuka Aerospace Mfg, Faro Technologies, Data Analysis teams and Aircraft Operations Directors reporting to the Air Force process and Dimensional Managers teams for improving the processes of the systems install using a automotive manufacturing style build process and certification system. Managing a 6 person staff of tool makers and metrologists.

• Managing and implementing new processes on the Northrop and Lockheed assembly floors worldwide. Developing new technology to meet the challenges of the increased manufacturing schedules.

• Building and integrating robotic laser/vision solutions to guide robotic drilling and measurement technology systems and train operations personnel onsite in the application, maintenance and troubleshooting of the systems.

• Implemented the acquisition of the new company Plymouth, MI Headquarters in Dec 2010, to expand operation capacities for Military and Aerospace business units to support 11 new Military programs. Moving the entire company within a 24 hours period and returning to fully operational status within a 48-hour period.

• Support team staff member in writing the AARG Patent profile to submit to the VRSI CEO to build a business case around how the program could be taken to the private sector and be made a commercial technology for use in many diverse applications.

• Responsibilities of my position:

Facility Services, co-coordinating all contractors and leading VRSI staff on maintenance of our Plymouth, Michigan

Facility. Grounds seasonal services and contracts, internal building codes and service repairs and updates. Security system and employee badge management and training for safety, fire, tornado and catastrophic situations.

Quality Management, created the Material Procurement Procedure (MPP) for all material and tooling entering the facilities, Quality systems designed around VRSI’s outlook to building relationships & working with vendors and building our Quality Stability Program (QSP) for supplying quality components in-process and final certification data to guarantee our J.I.T. delivery of our Laser / Vision products and engineering services to our customers. Our QSP provides run data real time and direct communication to the Quality Management group for minimal hold time regarding vendor and customer concerns and questions. Direct contact to our Military customers for all SBIR processes and controls that will be required to confidently assure a quality product delivered thru each phase of the program, providing data in formats designed by my Air Force counterparts to allow them to directly migrate data into phase evaluation reports. Hosting Dimensional Analysis conferences and presenting our findings and detailing the processes that have been created and refined for the implementation of cost stability and cost reduction. Logistics Management, managing the daily needs of the company D.O.T. and non D.O.T. vehicle fleet. Scheduling, service, training and budgets along with forecasts for new business and the support of the transportation and compliancy rules and regulations of the goods and services the vehicles are needed for. Health and Safety Officer, working with our ADP insurance agents and auditors to support the company’s safety culture and injury-free workplace behavior. Implementation of our 6 level safety program and compliance bonus program, providing both financial rewards and extra paid days off that benefits all VRSI employees.

Machine Shop Supervisor, managing a 4 person staff for specialty machining and fabrication including training and certifying in house welding and processes as well as shop equipment maintenance and training and implementation of Michigan OSHA safety practices. Budgeting for current equipment and future needs to support the growing in-house needs as our Aerospace and Automotive business unit grow and need a higher level of consistent quality work with a faster turnaround. THUNDER ENGINEERING INC.

Systems Applications Engineer:

Direct Hire to Metrologic Group Services Wixom, Michigan 10/2007 – 01/2010

• Responsibilities for all software implementation for the F-35 JOINT STRIKE FIGHTER Aircraft build at Northrop Grumman-Palmdale, Ca. and Lockheed Martin-Fort Worth, TX. Working with Engineering, QA, Facility Services and Wright Patterson Air Force Implementation teams for data integration of Laser Tracker, CMM and Theodolite measurement for Equipment, Tooling build and Certification for all tooling stations for the aircraft build sites.

• Define and engineer measurement programming for final customers’ requirements including Aircraft Engine and Structural components including Automotive and Industrial.

• Design Modular fixturing solutions and build along with customer team to integrate solution in measurement systems and train operations personnel in the application.

• Provide Point Cloud scanning services using FARO Arm and Tracker equipment in conjunction with Metrolog-XG measurement product.

• Demo, Audit & Application Engineering.

QMC - QUALITY METALCRAFT INC.

Mfg/Design/Release Engineer – Livonia, Michigan 03/2005 – 10/2007

• Responsibilities for all R&D scanning using the Faro Laser Arm for production & aftermarket components. thru Job1. Processing Polyworks data to provide cad designers baseline data to work from.

• Model components in cad, clay/foam or sketch for customer buy-in to program, lead meetings with design team with business case detailing the scope the project will take to implement. Designing components for functional processing and final customer satisfaction

• Design and implementation of robotic hemming cell & in-plant integration for production modules for PM-Caliber SRT in steel, LC22-Challenger in Aluminum. Work cell included robotic welding, mastic, material transfer in/out of hem anvil & pre-asm. Caliber program exceeded DCX requirements and set a STD to which the Belvedere Ill. plant worked their processing so the production would equal the prototype assemblies.

• Design Field Engineer for Street Car USA in Royal Oak, responsible for design details and install and assembly of the architectural steel staircases, steel trusses and mezzanine cable structuring. My group was responsible for the design implementation of the Chip Foose design for the Motor City Casino Stainless Steel roof build.

• R&D engineer for tool room die certification and 1st pc tool profile data collection for recut mastering.

• Created the QMC-SVO group, handling special programs, 66’Lincoln Speedster Custom car build, Street Car USA and Tier 2/3 customers with aftermarket ideas to take to market creating the Dodge Challenger Hood, the FOOSE Stallion hood using production inner hood structure assemblies from Ford Motor Company - Woodhaven Stamping plant.

DESIGN METAL INC.

Quality Assurance Manager – Oak Park, Michigan 02/2001 – 03/2005

• Primary customer contact after purchase order issue, handling Standards of Acceptance, promoting services,

Providing guidance to staff members. Working with customers to build the company's relationship.

• Programming the CMM with PC-DMIS V3.5 using customer supplied cad data and part prints. Conduct all buyoff validation studies and functions with staff and customers.

• Create prints and profile data for the Laser Dept. to build dimensional hold fixtures for the build team using Catia V5.

• Co-ordinate dimensional requirements for in-house manufacturing, customer buyoff and engineering validation of the measured data overlaid to customer supplied master data.

• Process and check all incoming data for changes and update prints and document controls for ISO. Calibrate and maintain all company and employee tools.

• Attend supplier meetings to better communicate and reinforce the business unit’s communication of availability to support the customer.

THREE-M TOOL & MACHINE INC.

Materials Manager – Walled Lake, MI 06/2000 - 02/2001

• Developed and implemented IT Bill of Materials system for team functionality.

• Responsibilities for all material movement in and out of the plant, Vendor services and internal department schedules for material flowing in- house.

• Purchasing duties included vendor ordering on standard purchases & critical issues, visiting vendors to develop and building stronger relations to better both organizations as team players.

• Led the support team to the Engineering Department for reverse engineering data from the Quality Dept. supporting the CMM/Metrology programming group. Supporting the ISO Implementation Team.

• Team member of the ISO Implementation Team.

CTS - CREATIVE TECHNOLOGY SERVICES (Masco Corp - MSXi) FDA Compliance / QA Supervisor – Canton, Michigan 03/1999 - 06/2000

• Led Whitmore Lake project for the FDA audit on the first review without any nonconformance’s and received plant acceptance for regulatory systems implementation.

• Responsible for designing and implementation of Metrology Lab to exceed the FDA requirements for Medical Inspection in the Whitmore Lake Plant.

• Selecting Equipment and personnel to support the program. CMM programming with Virtual- DMIS, Fixtures & Gauges created using using OMNI Structures Modular Tooling Systems saving $285,000.00 in dedicated tooling.

• This position required the organization of all incoming materials and documentation in detail for regulatory Compliance to the FDA.

• Researched and developed acceptance testing for FDA components, including component and assembly tooling testing and validation with on going revisions applying to systems and regulatory compliance review.

CMM SOLUTIONS INC.

Senior Applications Engineer – Union Lake, Michigan 08/1998 – 03/1999

• Responsible for Quoting and Programming specific customer programs using off- line CMM programming systems.

• This position required in-depth customer contact and communication with the individual inspection groups and Program Management Teams & Internal CMM Solutions staff. Programming software systems Silma SimStation V 3.1 and PC-DMIS for Windows.

• Applications programmer for aircraft components coordinating validation controls, documentation for dimensional engineering.

CPM - CONTROLLED PRECISION MACHINING INC,

Quality Assurance Manager – Farmington Hills, Michigan 10/1997 – 07/1998

• Establishing ISO-9001 Systems, Floor inspections: 1st article, in-progress and final audits. Customer Relations.

• Engineering duties: CAD to NC-CAM, Progressive Gage and Calibration system, Operational outside vendor activities. Shipping & Receiving accuracy and communication with customers regarding timing and tracking.

• Implemented Process controls for revisions and customer documentation. GREENFIELD DIE & MANUFACTURING INC,

Metrology Manager – Canton, Michigan 06/1993– 10/1997 Measurement Dept. Operations:

• CMM programming of components, Gage R&R studies, Plate Layouts

• Implemented designing and building Laser fixture programming reverse engineering with the CMM.

• Led R&D department for laser cut parts buyoff 1st piece program to run with only 1 setup part.

• Supervision of the four Inspectors / Two shifts w/scheduling of the work and the staff.

• Main contact for Tool and Part buyoff, providing customers and engineering with detailed surface models of the final accepted die and parts for future issue review and remanufacturing process. Saving the customer valuable costs and tool down time for repairs. EDUCATION, LICENSES and CERTIFICATES:

Diploma

Major: Accounting/Machine Tool

Livonia Bentley, MI

GD&T,CRRT,SME,, Society of Manufacturing Engineers, MI PC-DMIS 2016 Windows & DOS versions, Automation Software (Brown & Sharpe), RI Datapage R/T, Dataview, Automation Software (Brown & Sharpe/ Hexagon), RI GMP-QSR Regulatory Compliance Standards, AAMI - FDA, DC Mitutoyo 2100, 2000, Mitutoyo Corp., IL

Certfications/Skills and Abilities:

ISO/TS-16949-2009

IATF-16949

Lead Auditor - AIAG

Catia V5/V6.

Metrolog XG 12.001HF5c/ Silma XG 12.001HF4

PolyWorks 14.0

Insite 2.0

Quality Control Systems, ISO-9000, CAD skilled, CMM programming in PC-DMIS DOS & Windows versions thru DMIS 2016

Geo-Pak 200, 300, 2000,2100,

CADKEY95, 97 Auto CAD 14

Modular Fixturing – Design and Practical Assessment to build Microsoft OFFICE 2000/2017:

GD&T, Faro Anthro- Cam for windows. (Cim-Station) Silma V3.1. GMP-QSR

Instron Tensile Equipment and Fixturing

Honors and Activities:

SME member, Society of Quality Assurance.

Notes and Other Information:

Reverse engineering applications, scanning, Appling the "how too" and the interaction between the CMM & CAD to define data reports for validation.

Contact this candidate