Quality Engineer Level 1

Ryan O. Cook

*** ****** **** ***** #*** Murfreesboro, TN

Email: *******@*******.*** 704-***-****

Summary

Six Sigma Blackbelt and Lean Manufacturing executive with over 24 years of cross-functional experience of increasing productivity, cutting cost, improving delivery, reducing scrap, and improving safety. Innovative leader with the ability to create strategies and set goals that deliver results. Able to facilitate, lead, or participate in a team atmosphere across organizational boundaries to optimize the business key performance indicators.

Experience

IAC 11/2021 – Present

Quality Engineer for Injection Molding Contractor

All phases of PPAP from Level 1 to Level 5

All the tools of APQP

Writing Work Instructions

Corrective and Preventive Actions

Assisted with IATF Certification

Prepared PFMEA, Control Plans, Process Flow Diagrams, etc

Root cause analysis

Responsible for 8D;s and Quality Alert

Tesla 08/21 – 10/21

Supplier Quality Engineer Contractor

Helped to develop suppliers

Approved supplier PPAP’s

Initiated 8D’s and supplier preventive/corrective actions

Communicated back to suppliers defects

Ficosa

Quality Engineer for Injection Molding and Paint 03/21 – 08/21

Side Mirror Manufacturer for Ford, Chrysler, FCA, Volkswagon, and Audi

All phases of PPAP from Level 1 to Level 5

All the tools of APQP

Writing Work Instructions

Corrective and Preventive Actions

Assisted with IATF Certification

Prepared PFMEA, Control Plans, Process Flow Diagrams, etc

Root cause analysis

Responsible for 8D;s and Quality Alerts

Tachi=S

Quality Inspector 05/20 – 03/21

Seat Manufacturer for Nissan

Steamed cleaned rear seats for final shipment

Final inspection of rear seats for final shipment

Tested front seats for shipment

Ironed front seats for final shipment

Final inspected front seats for shipment

Feintool

Quality Engineer ( Laid Off ) 05/18 – 11/19

Fineblanking and Forming Company

Must have knowledge of GD&T

All phases of PPAP from Level 1 to Level 5

All the tools of APQP

Writing Work Instructions

Corrective and Preventive Actions

Assisted with IATF Certification

Prepared PFMEA, Control Plans, Process Flow Diagrams, etc

Root cause analysis

Interpret CMM results

Chassix

Quality Engineer ( Contract) 02/18 - 03/18

Aluminum, Iron, and Steel CMust asting and Machining Company

Helped with the tools of APQP

Helped prepare PFMEA

Helped prepare Process Control Charts

Helped prepare Process flow Diagrams

Helped prepare Work Instructions

Hobbs Bonded Fibers 08/17 – 11/17

Quality Manager ( Contract )

Led continuous efforts across plant

Utilized Lean techniques to increase productivity

Tensile and Elongation Teasting

Corrective Actions and Preventive Actions

Everyday daily management

Root cause analysis

Shiroki 07/17 – 08/17

Quality Engineer ( Contract )

Helped prepare PPAP

Helped with the tools of APQP

Helped prepare PFEMA and Control Plans

Read blue prints and had a pretty good understanding

Utilized MSA equipment

Assisted in TS Certification

Root cause analysis

Adient 02/17 – 06/17

Supplier Quality Engineer ( Contract )

Helped supplier organize and prioritize according to cost structure

Utilized Lean techniques to increase productivity

Decreased headcount 5%

Root cause analysis

Nissan North America Smryna, TN 08/15 – 02/17

Process/Quality Engineer ( Contract )

Automotive Manufacturer

Helped identify over $4.5 million of cost savings at Stamping supplier

Assisted in identifying $250K cost savings at supplier by line rebalancing and redefining material handling routes

Assisted in identifying and implementing $144K cost savings at supplier through line rebalance

Assisted in $180K cost avoidance by doing times studies reallocating work elements to operators and $145k cost savings within our Canton plant by reallocating work elements to material handlers

Helped put together logistics proposal that has a potential of $400K cost savings by eliminating storage warehouse

Working with team to bring processes back in house from suppliers which would have a potential of more than $250K cost savings

Identified and started implementation plan for 3rd party sort which has a potential cost savings of $6.5 million annually

Helped prepare PPAP

Helped with the tools of APQP

Helped prepare PFEMA

Read blue prints and had a pretty good understanding

Utilized MSA equipment

Shiloh Industries, Dickson, TN 11/14 – 6/15

Value Stream Manager

Manufacturer Complex/Simple Welding Assemblies for Wire

Reduced headcount 20% ( 170 to 136 ) while sales increase from 5.5M to 7.1M cost savings

Utilized Lean Techniques to increase productivity through the implementation Flow racks and Water spiders

Redesigned cell layouts to increase productivity and PPAP

Helped write standard work for Supervisors and Team Leaders to hold them accountable for daily activities

Gave management team proposal for setup reduction of 75% on stamping presses

Helped prepare PPAP

Helped with the tools of APQP

Helped prepare PFEMA and Control Plans

Read blue prints and had a pretty good understanding

Utilized MSA equipment

Devro Swansea, SC 03/13 - 11/14

Continuous Improvement Manager 03/13 – 01/14

Quality Improvement Manager 01/14 – 01/14

Food Manufacture Sausage Casing

Helped win a 20 million dollar account by providing Quality data that reduced the customer defect rate 95%

Decrease customer defect rate 80% by finding true root cause and saving a 5 million dollar account

Led Standard work event that increased productivity 50% within our Delime process

Helped reduce solid variation 60% and improve yield 2% for cost savings of $2.0 million

Reduced scrap 50% due to moisture reduction cost savings of $500K

Established measurement system to capture all scrap within Processing Department

Helped establish 5S audit system plant wide

Assisted/Participated in Value Streaming event

Assisted in Process FMEA event

Helped improved inventory accuracy from 12% to 98%

Created FIFO system for materials and WIP plant wide

Root cause analysis

Chemtura Biolab Conyers,GA 02/12 – 03/13

Process Engineer Manufacture Chemical Pools

Implemented plantwide downtime database

Helped productivity 26% on main production line

Helped reduce downtime 40% on main production line

Helped reduce lid scrap rate 20%

Husqvarna Outdoor Products 03/11 – 02/12

Process Owner Weld Department

Manufacture Tractors for Lawn Cutting

Reduce overtime 60%

Improved productivity 30%

Improved on time delivery 85%

Reduce scrap 90%

AFL Telecommunications, Duncan, South Carolina 11/09 – 03/11

Manufacturing Engineer/Production Manager

Wire drawing for Utilities and Fiber Optics

Supervise direct reports and to have the primary supporting role to insure the safety, quality, productivity, delivery, and cost of the manufacturing operation meets or exceeds the company's goals.

Reduced WIP variance 80%

Helped reduce wire break rate 75% and annual cost savings of $350K

Helped increase throughput 10%

Helped increase productivity 15%

0 lost time accidents this year, 4 lost time accidents 2009

Luvata Grenada LLC, Grenada Mississippi 6/08 – 2/09

Operations Manager ( 670 employees ) { 230 report to me 2 shifts 30 indirect 200 direct }

Manufactures coils for HVAC business

Increased on time delivery from 57.7% to 84.7%

Improved Productivity from 43% to 68% ( 44% defect reduction approx. 350 K annualized savings )

Reduced overtime from 34% to 12% ( 65% defect reduction approx. a 200K annualized savings )

0 OSHA recordables since June

Reduced external defects from 5738 ppm to 877 ppm ( 85% defect reduction approx. 20K cost avoidance )

Currently training hourly associates on Six Sigma and Lean Techniques

Carrier Transicold Corporation, Charlotte, NC (350 employees 3/06 – 2/08

Manufacturing company - air conditioners. Responsible for managing 40 employees. Manufacturing Supervisor

Improved productivity 100% and reduced overtime 80% by applying lean techniques.

Helped to reduce inventory 25% by triggering materials a different way and by implementing a cycle count program without adding headcount.

Helped to increase on time delivery from 87% to 98%.

OSHA recordables went from 7 to 3 with no lost time accidents.

Danaher Controls (Joslyn Clark Controls) Lancaster, SC (250 employees) 7/00 – 3/06

Quality Manager/ Value Stream Manager /Danaher Business Systems Manager (Kaizen Continuous Improvement)

Responsible for 35 direct reports 5 salary and 30 hourly associates. Responsible for quality program that manufactures Nuclear related safety limit switches and quality program for government related contracts. Responsibilities include selection of suppliers, auditing suppliers for compliance, maintaining traceability off all components that go into switch as well as switch itself, following the guidelines of Nuclear Regulatory Commission (NRC) and NUPIC which are the power utilities who set the guidelines for providing safety related products to the industry. Responsible for resolving daily quality/supplier issues.

Manage 16 million dollar business in which inventory was reduced 20%, on time delivery 50% from 79.2% to 89.9%, increased productivity 20% basically driven by Kaizen activity, reduced OSHA recordables 200% from 3 to 1 through the use of 5S, improved quality external and internal 30% through the use of Six Sigma methodology.

Develop quality initiatives which support a $50 million dollar business in which we manufacture Nuclear and Commercial limit switches, electrical and mechanical chart recorders, proximity switches, light curtains, vacuum contactors, medium voltage controllers, fire pumps, and various types of elements.

Participate/Lead monthly Kaizen teams ( Value Stream Mapping, Variance Reduction Kaizen, Standard Work, SMED, Danaher Materials Process ) which have decreased process cycle times by 60%, increased productivity 45%, decreased scrap 30% – 75%, reduced internal defects 65%, decreased warranty returns 80%, and a cost savings of approximately $250 K.

Utilized Six Sigma techniques to reduce scrap 85%, warranty returns 95%, and a cost savings of $60 K for our solenoid product line.

Utilizing Six Sigma techniques to eliminate 80% of scrap and rework in our SMT board operation which will yield a cost savings of $225K.

Started process to help achieve ISO 9001 certification by March 2007.

Developing new supplier for vacuum contactors which will yield a cost savings of $300 K to business.

Mack Trucks, Winnsboro, SC (2500 employees) 8/99 – 7/00

Supplier Quality Assurance Engineer

Responsible for using the Six Sigma Tools and Techniques to determine root cause and solve supplier related defects as well as internal defects that result in poor quality, rework cost to the business, added cycle time, and increased variation in the product we make.

Assisted in reducing supplier defect rate by 30%.

General Electric Industrial Systems, Salisbury, NC (3000 employees) 5/93 - 7/99

Six Sigma Quality Blackbelt (1998-1999)

Developed vision and strategy for Quality driven projects within the plant. Responsible for developing training matrix for hourly/salary employees on Six Sigma initiatives. Work with cross functional teams to determine root cause and solve problems that continue to plague business.

Responsible for maintaining and driving cost out projects to meet 2.1 million dollar commitment on variable cost productivity.

Led project that took on time delivery from 69% to 92% and yielded $200K of cost savings to business.

Led project that took unit ship from 1.58 shipments per order to 1.2 shipments per order and a cost savings of $170K

General Electric Medical Systems, Waukesha, WI -Technical Leadership Program (Manufacturing/Sourcing Track)

Strategic Sourcing Leader (2/98 - 7/98)

Negotiates prices with suppliers, worked closely with New Product Programs to assist in proper phase in phase out issues, managed a productivity funnel for MR Modality in which we were responsible for taking $35.4 million out of the budget, and helped suppliers get productivity projects implemented with engineering. Negotiated with suppliers on Plastic parts (machining part, injection molding, and rotor molded parts), Fiberglass enclosures and Electrical components (circuit boards, cardiac pads, etc.).

General Electric Medical Systems, New Berlin, WI - Technical Leadership Program (Manufacturing/Sourcing Track)

Production Team Leader (8/97 - 2/98)

Led 26 people in Detector Module Assembly for Computer Tomography, increased productivity by 10%, had a 22% scrap reduction, no OSHA recordables, had a 15% increase in volume and never shorted a customer.

General Electric Medical Systems, Florence, SC - Technical Leadership Program (Manufacturing/Sourcing Track) Process Engineer (2/97 - 8/97)

Maintained workstation instructions, worked with production associates to improve manufacturing processes.

Implemented Six Sigma project which led to a $300K to $700K savings annually, and finished another project which led to a 20% increase in productivity and a cost savings of $3K annually.

Six Sigma Greenbelt trained and Certified

General Electric Medical Systems, Florence, SC - Technical Leadership Program (Manufacturing/Sourcing Track)

Process Engineer (8/96 - 2/97)

Maintained workstation instructions, programmed CNC filament wind machines, worked with production associates to improve manufacturing processes, supported near net shape project that will decrease cycle time 20% and save materials, increased team productivity by 15%, and supported projects that helped reduce the cure time of fiberglass structures.

Education

Southern Illinois University-Carbondale, IL

Bachelors of Science, Electrical Engineering Technology; May 1992

Minor: Mathematics Specialization: Statistics

Awards

1999 United Way Co-Chair

1998 TLP Recognition Award

1997 Mentoring Program

1995 General Electric Whitney Technical Achievement Award

1994 General Electric Student Intern Award

National Society of Black Engineers

Prince Hall Masons

Skills

SAS, Microsoft Office, GE Flow Tech, ProModel, CadVance 5.0, Visio, Minitab, SAP, Oracle

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