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Quality Engineer Injection Molding

Durham, NC
March 19, 2020

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*** ********* ****

Mooresville, NC 28115

(Cell) 336-***-****


Morehead State University, Morehead, KY


Bachelor of Science in Engineering Physics/Minor in Mathematics

University of Kentucky, Lexington, KY


Bachelor of Science in Mechanical Engineering (15 hours to complete)


ASQ Certified Quality Engineer (CQE)

ASQ Certified Six Sigma Black Belt.


10/13 –Present. Ingersoll Rand


Quality Manager

Provided plant leadership and direction for quality and continuous improvement from suppliers, internal process to customers

oOil Free, Contact Cooled, & Reciprocating air compressors units

Managed Quality KPI’s: DPPM, FPY, and COPQ for Warranty, and Scrap/Rework through MRB

Developed and lead SCAR’s and Internal CAR systems

Managed quality for new product launches through APQP

oEstablished CTQ’s and Early Launch Containment Plans

oEstablished PPAP and DVP&R glide paths.

Managed QMS and Internal Audit process to ISO9001

Lead Supplier Improvement Programs (SIP’s)

Location: Mocksville, NC


Implemented Quality MDI (Manage for Daily Improvement) to improve PPM, FPY & MRB

Trained quality member’s use of PDCA, Fast Response on critical few, 8D methodology, and PFMEA.

oReduced PPM by 60%

oImproved FPY from average of 60% per month to 83%

oReduced MRB total from over $100K to $50K in 3 months

oReduced warranty dollars by 15%.

Location: Campbellsville, KY


Implemented MRB process to support Scrap and Rework reduction.

Implemented change control process

Implemented statistical methods by personally training quality staff (Gage R&R, & Capability Studies)

Reduced plant PPM by 55% through supplier, internal process, and design improvements.

Lead team to improve QMS and acquire ISO-9001 2015 certification

oRevamped internal auditing process

Quality Engineer


Implementing automotive quality systems

oPPAP’s for suppliers and internal processes

oPFMEA’s activities and concepts for process development

o Control Plans & Method Sheets

oAPQP for new product launch

Project leader for new product development projects through APQP system

oLaunched 3 new compressor models.

Lead and set up quality system for IR’s first starter production cell

oHigh level of poke yoke system through PFMEA activity

Lead RIE (Rapid Improvement Events)

5/01- 10/13. Hitachi Automotive Systems Americas, Harrodsburg, KY


Quality Assurance Manager


Manage quality for all Electronic Control Units built at Harrodsburg plant, and internal injection molding

oResponsible for 10 customers, 19 production processes, and 14 Engineers

oTier 1 OEM experience with Nissan, Honda, GM, Toyota, and Chrysler.

Implementing Six Sigma methodology

oChampion projects & training Black Belts

Changing the culture to “Do the job right the first time”.

Trained manufacturing Engineers proper DOE techniques (Full and Fraction Factorial)

Product Line Quality Engineer (ASQ: CQE, CSSBB)


Responsible for programs from supplier to customer

Working with production for defect reduction, continuous product/process improvements

Layered & process audits

Working closely with customers to assure satisfaction through

oAnalyzing returns for failure modes & root cause.

oRectifying process with containment, corrective actions, & mistake proofing (Global Implementation)

oWriting and submitting 8-D & 5P Reports

oPPAP testing/submission for all new products launches and/or process changes

Working closely with suppliers to assure quality satisfaction through

oProcess audits

oPPAP requirements, and approvals

oIssuing corrective actions, and approving of 8-D reports.

Chairing meetings with cross functional teams, internal management, customers, & suppliers

Leading APQP programs

Designing and conducting validation for new product/process changes

Supporting design reviews for product manufacturability, and quality through durability & reliability

Creating/updating PFMEA’s, and Control Plans.

Project Management for new launches.


Helped reduce PPM from over 1,000 to below 20 within 4 months

Managed & launched first GM & Honda ECU programs at Hitachi

Managed & launched first Electrical Power Steering module program at Hitachi

Conducted Six-Sigma project saving $1 million per year

Set up quality program for internal injection molding plant

Launched quality system for new ECU building

Assisted in implementing a global lessons learned database for Hitachi Auto plants worldwide


Measurement System Analysis

Capability studies (Cp/Cpk analysis)

Hypothesis testing

Attribute & Variable control charts


7 quality tools

7 quality management techniques

Proficient in Minitab

Project management

Lean Principles & Improvement techniques through Six Sigma DMAIC process.

A3 thinking

9-step problem solving

Design 7 ways / 3P thinking

MDI (Manage for Daily Improvement)

Leadership Skills

oServant Leader, Inverted Pyramid

oSituational Leadership

oCritical Conversation

oMotivation as teacher

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