Quality Engineer Continuous Improvement
Resume:
Russell Terrell
Quality Engineer
Lean Six Sigma Black Belt
Leasburg, N.C
Home: 336-***-****
Email: *******.***********@*****.***
Summary: Innovative Lean Six Sigma Black Belt with strong knowledge and hands on experience with continuous improvement teams that focus on reducing process variation and defects for the internal and external customers. A team-oriented engineer with proven success utilizing root cause analysis, defect reduction, value stream mapping, changeover analysis and standard work to facilitate the cross functional team efforts to meet business goals and increasing customer demands. Enjoys working with others in a fast-paced environment to find practical solutions to business challenges. Have to ability to bring energy, enthusiasm, and a spirit of cooperation to any organization. Over the past five I have led over 90 continuous improvement project netting over 4.7MM
PROFESSIONAL EXPERIENCE
GKN DRIVELINE, Roxboro, NC
Quality Engineer 2023 November - Present
Assisted with small teams for Toyota involving warranty issues, internal / external failures. Applied A3, 5 why, Ishikawa, short term and long-term countermeasures to resolve concerns and prevent future occurrences.
Actively worked with cell members and posted quality alerts drafted sorting criteria and verified all on site material was clear of defective parts.
REVLON – Oxford, NC
Sr. Staff Quality Engineer 2011-2023
Reported QAKPIs for six facilities to senior management on a monthly basis. Conducted surveys worldwide and provided feedback to manufacturing as well as component suppliers.
Completed material use cost reduction projects totaling over $ 500,000 this past year. Participated monthly on CI teams to reduce scrap, downtime, in process defects and enhanced automated data collection systems.
GKN DRIVELINE, Mebane, NC
Continuous Improvement Engineer (Plant layoff due to product demand) 2008-2009
· Assisted monthly Kaizen events: Reduced changeover time by 33 % (3 hours) in the shaft department.
· Conducted over forty cost reduction studies and presented to staff, highlighting savings and cost up to 1.5 million.
· Developed / amended over 30 routers for each phase of production based on complexity and cycle time.
· Maintained plant capacity (6 million units) for all production lines, based on capability and feasibility.
· Assisted the finance team with budget process for 2008-2009 and served on business improvement team to remove nonvalue added activities from current process. The team identified all value-added processes and I developed a checklist for all static data.
BRISTOL-MYERS SQUIBB, Greensboro, NC
Lean Six Sigma Black Belt Project Engineer (Contract Position) 2007-2008
· Initiated cost reduction processes that reduced changeover time by 30 % utilizing standard set-up and training program.
· Implemented a plant wide program to monitor change over time, mechanical down time, percent defective, scrap, and planned production versus actual output (attainment) using pivot tables to capture data and graph. Utilized Hypothesis Testing comparison for two key products to maximize fluid uptake in finished product.
Modified (PLC) Programmable Logic Controls to ensure product was formulated based on internal specifications.
TRIEM ELECTRIC MOTORS, Mebane, NC
Quality Assurance Manager (Plant layoff due to product demand) 2006-2007
· I utilized cellular production techniques to increased efficiency by 20-30 percent in the motor winding cell.
· Assisted team leaders to improve processes using six sigma techniques, SPC, training, root cause analysis, standard work procedure as well as tracking production verses in-process defects with Mini Tab software.
Russell Terrell
Quality Engineer
Lean Six Sigma Black Belt
815 Elmore Drive
Leasburg, N.C
Home: 336-***-****
Email: *******.***********@*****.***
LUNA INNOVATIONS NANOWOKS DIVISION, Danville, VA
Senior Reactor Lab Engineer (Contract Position) 2006-2006
· Perform test / experiments (ANOVA) to optimize the production of carbon nanotubes using an electric arc plasma reactor.
· Tracked daily production and increase first pass yield by 40 % with the DMAIC six sigma methodologies.
Installed a new reactor with modifications to improve yield, reduce change over time frame and process repeatability.
NORTH AMERICAN AERODYNAMICS, Roxboro, NC
Operations Manager (Company lost major Military Contract – Layoff) 2002-2005
· Developed and wrote ISO 9002:2000 manual and implemented procedures for ISO military compliance for parachute manufacturing.
· Directed all governmental contracts, designed an automated program to track production, quality, and machinery efficiency and track operator performance to reduction in process failures by 28% rework savings of $880,000.
· Set up program to monitor all off standard functions based on each department and operator. This program reduced in process defects by 30 percent and finished product rejections by 26 percent.
· Served as liaison between government quality inspection officer and manufacturing to ensure military specifications were met or exceeded.
GENERAL ELECTRIC INDUSTRIAL SYSTEMS, Mebane, NC
Manufacturing Engineer (Contract Position) 1999-2002
· Directed efforts of team leaders and shop floor manager with production, quality and tooling concerns as it relates to Motor Control Panels while reducing case defects by 33 percent.
· Initiated plant wide program to track production performance versus quality defects in a real time basis, as well as generating real time reports with annual saving of $330,000.
PLASTIC INGENUITY, Oxford, NC
Quality Engineer ` 1997-1999
I instructed SPC / Process control charting and metrology for all measuring devices.
Resolved customer complaints / issues by organizing teams and implementing production process improvements based on quality related issues as well as corrective action plans to eliminate future occurrence.
Reduced scrap rate by 15 % by applying SPC to critical processes for an annual savings of $ 240,000.
CLAIREMONT ELECTRONICS, Yanceyville, N.C.
Project Manager (Contract Position) 1997-1997
· Assisted contractors and corporate engineering director in plant construction (new facility) and production line set up.
Installed standards and routings into the MRP system-based cycle time and historical data.
Developed all new associate training and composed detailed manufacturing standard work instructions.
INTERNATIONAL PAPER, Durham, NC
Quality Assurance Manager (Plant Relocated to VA.) 1996-1997
· Effectively implemented new Quality Assurance program to ensure quality objectives and reduced defects by 25%.
Managed the Quality Lab, raw material testing and inspection lab and capabilities studies.
Worked in conjunction with customer certification program to become a certified vendor.
Managed all complaints / rejections from supplier to customer and initiated corrective action plans to prevent future occurrences.
EDUCATION
BSIE, North Carolina A & T State University
A.A.S., Durham Community College, Dental Lab Science
PROFESSIONAL TRAINING
Certified Lean Six Sigma Black Belt, Alamance Community College (110 Course Hours plus Project)
Certified Lean Six Sigma Green Belt, Alamance Community College (80 Course Hours)
Certified Six Sigma Green Belts, General Electric
Certified Web Master. International Paper / NC State
Certified Quality Engineer/Manger, International Paper
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