Quality Engineer Manager

KOSHY SACHARIAH

*** ******* *****, *******, ** **666

eMail: *****.*********@*****.*** 201-***-**** (C) PROFILE

Extensive Experience in Quality Engineering & Management; An Enthusiastic Results Oriented Professional who possesses a Strong Customer Focus, who Consistently delivers High Quality Results, and takes Pride in Doing a Good Job and Achieving Results. ASQ Certified Quality Engineer, Volunteer for North Jersey ASQ Executive Board (Monthly meetings Arrangements Chair). SELECTED ACHIEVEMENTS

Implemented and Certified five Plants to ISO 9001, 9 calibration labs to ISO17025. One each to IATF-16949 and ISO-13485. Quality Manager for Successful New Plant Start Up. Hired, Trained and Certified personnel to perform multi-functional tasks. Incorporated Quality improvement using Statistical techniques and 6 Sigma Tools; Certified Green Belt. Self-trained Excel programmer for calibration and test programs.

EMPLOYMENT HISTORY:

Quality Engineer: Weiss-Aug Inc. East Hanover, NJ 06/2017-Present Manufacturer of Precision Stampings and Moldings for the Automotive, Medical, Aerospace and other Industries

Managed IATF 16949- 2016, AIAG Sanctioned Interpretations, ISO 9001-2015, ISO 13485-2016 External 3rd party Registrar and Customer audits; Customized and upgraded changes from previous standards to current versions; Managed organization metrics for both IATF and ISO 13485, Updated/managed Quality databases for monthly scorecards – Internal rejections, Customer complaints/ 8Ds, Established Supplier IATF certifications based on risk, CSRs, FMEAs, Control Plans, PPAP, AQPQ.

Scheduled/Lead/Performed internal, process audits based on risks, managed internal & external calibrations, furnace calibrations to AMS & CQI requirements, PPMs; Manage the training programs, data bases, records.

Manage document change control process; Records storage; Document Management Review Meeting Minutes Quality Manager: Hytorc/Jetyd Corp. Hackensack & Mahwah, NJ 01/2008-06/2017 Manufacturer of High Load Bolting/Clamping Equipments for Heavy Industrial and Nuclear Applications

Quality Management Representative for ISO 9001-2008 that also included Design; Obtained and maintained certifications for 4 organizations: Hytorc, Jetyd, Hytorc Wind, & Torque Gun Co. Created complex Excel based software programs for calibrations that included macros. Handled External 3rd party and customer audits.

Obtained certifications to ISO17025 at 9 locations performing calibrations. Worked with customers and all stake holders to create customer unique Quality Plans detailing all requirements of processes, inspections and tests, including international nuclear applications.

Obtained CE/ETL certifications for products sold in Europe & Asia; created the Health, Safety & Environmental Manual.

Automated Nuclear and other Customer Material Certification, Calibration reports using Excel Programming. Quality Manager: Microtube Fabricators Inc (Div of Handy & Harmon Corp), Middlesex, NJ 2004-2008 Fabricators of Stainless Steel and Specialty Alloy Tubing for the Medical/Surgical, Electronics and Other Industries.

Upgraded plant from ISO9002-1994 to ISO9001-2000 standards. Responsible for all 2nd and 3rd party audits.

Responsible for performing process/product validations: IQ, OQ & PQ.

Promoted to Program Manager on a new product working closely with Customers, Suppliers and all internal departments. Process/Quality Engineer: Honeywell, Defense Avionics Systems, Teterboro, NJ 2000-2004 Formerly Bendix, then Allied Signal, Honeywell Teterboro is a global Defense Avionics and Aerospace Products Prime Contractor.

Quality responsibility for various Military and Commercial Avionics Programs: C130, F15, F2, F22, T50, Comanche Aircrafts, in an ISO 9000 and AS 9000 environments.

Delivered 99.9% defect free products to customer; Sigma levels ranging from 3.6 to 6.

Responsible for Product Selloffs and Process Audits to/by Government Agencies (DCMA) and Customers (Boeing, Lockheed). Awarded Certificate of Achievement by Boeing Recognizing Exceptional Performance.

Ensured Supply Chain and Internal Processes produced Quality products. Responsible for Design Reviews; FAI; Phase Gate Reviews; MRBs; RCCA; Qualification Tests; Environmental Stress Tests (ESS); etc. Quality Assurance Manager: Stull Technologies, Somerset, NJ 1998-2000 Injection Molders, Closures Technology. Manufactured caps for bottles of such household products as: Loreal, Revlon, French’s mustard, Hunts ketchup, Elmer’s glue, Clairol, Alcon Saline Solutions, etc.

Quality Responsibility for a Fast Paced “Lean Manufacturing” Plant operating in 3 shifts, in compliance to FDA requirements. Managed and operated the Quality Labs, managing 8 employees.

Developed spread sheet programs to automate unique testing and chartings requirements of customers. This resulted in auto generation of C of C with full range of all test results on the CoC, in minutes, rather than hours.

Visited customer facility to address customer concerns and complaints. Institute RCCPA.

Developed manpower Requirements, etc.

Quality Assurance Manager: Coining Corp. of America, Saddle Brook, NJ 1996-1998 Solder & Brazing Preforms Manufacturer used in the Electronics Industry

Successfully Designed, prepared, and Certified the facility to ISO 9000. The Lloyd’s audit resulted in Zero Audit Findings. Supervised employees.

Extensively developed computer data bases (Calibration Records, Internal Audits, Quality Manual, Customer Complaints, etc.) to improve traceability and accessibility.

Quality Assurance Manager: Tempo Technology Corp., Somerset, NJ 1991-1996 Synthetic Diamond Manufacturer - Manufactured Industrial Diamond from Carbon in a Production Environment.

Responsible for the set-up and management of the Quality Assurance/Control Functions as the company transitioned from a R&D Company to a Production company.

Developed and implemented Quality Manuals. Set-up procedures and standards for inspection and testing from raw Materials to finished products. Hired, trained and supervised personnel. Schindler/Westinghouse Elevator Corp.: 2nd Largest Elevator & Escalator Company in the US: Design, Manufacture, install & maintain elevators and escalators. 1986-1991

Quality Assurance Manager: Clinton, NC, Escalator Manufacturing Plant (4/90-11/ 91).

Picked by the Co. to Set-Up QA and QC in a New Plant to produce Escalators. New Plant Start Up Activities Involved Hiring, Training, Supervision and working with them, to perform cross functional tasks, to produce Quality Escalators.

Apart from QA & QC, responsibilities also included Order Writing, Receiving, Shipping, and Stock Rooms functions.

Designed, prepared, and Certified the plant to ISO 9000 within the tight time schedules established by Upper Management.

Interfaced with all Levels and functions of the company, suppliers and customers to achieve Quality objectives.

Implemented the supplier dock to stock program.

Quality Engineer: Schindler/Westinghouse, Morristown/Randolph, NJ, (5/86-3/90).

Managed the Quality Processes in a Plant in process of being shut down as products were outsourced to both Domestic and Overseas Suppliers.

Traveled extensively to both Domestic and Overseas Suppliers to Implement and Audit Quality processes and Products. Trained Inspectors in Source Inspections and in-Process Audits at Supplier Facilities. Reduced Field Quality Installation Problems due to Product Manufacturing Non-conformances by 90% in a 3-yr. period.

Visited various Customer sites to comprehend problems, and institute corrective actions. Quality/Metallurgical Engineer: Welles Mfg. Corp., Northvale, NJ 1982-1986 OEM & after market automotive engine components Manufacturer

Chosen by the company to undertake SPC training at Ford Motor’s Co. Dearborn, MI, followed by in-house SPC implementation. Created Control Plans, Process FMEAs, implemented various charting techniques: X-bar, R charts, moving range charts, etc. Performed Gage R & R studies; Capability studies; Calculated CpK and other Capability indices; Pareto & Histograms; Various attribute and continuous Sampling plans.

Used DOE tools to improve productivity and tool life etc.; wrote CMM programs.

Managed Metallurgical Labs.

Handled Ford, GM, Chrysler, IH, Caterpillar, and other OEM customer audits.

Established process and product standards for various operations. Established process standards for hardening of carburized shafts that eliminated “soft spots”, thereby eliminating a constant source of customer rejections. EDUCATION & PROFESSIONAL DEVELOPMENT:

Master of Science, Metallurgical Engineering, Polytechnic Institute of New York, NY: GPA 3.75/4.00 Formal education and training on:

Certified Six Sigma Green Belt; SPC; Project Management; Non-Destructive Exam: UT; MT, PT: Level II; Cordax CMM Programming; Management Courses; GMPs For Medical Device Manufacturing (21 CFR Part 820-Quality System Regulation; ISO 13485); Certified Soldering & CCA Inspections to MIL-STD-2000, 2000A, MIL-S-45743; Lean Manufacturing, 5S, Safety; Excel, Access HTML, CSS, Dreamweaver Website Designs.

AFFLIATIONS: Member, American Society for Quality; ASQ Certified Quality Engineer

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