Quality Engineer Injection Molding

SHANNON LUMPKINS

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

Mooresville, NC 28115

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

adcdef@r.postjobfree.com

EDUCATION & CERTIFICATIONS:

Morehead State University, Morehead, KY

*/**-**/**

Bachelor of Science in Engineering Physics/Minor in Mathematics

University of Kentucky, Lexington, KY

8/01-12/08

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

Certifications:

ASQ Certified Quality Engineer (CQE)

ASQ Certified Six Sigma Black Belt.

EMPLOYMENT HISTORY:

10/13 –Present. Ingersoll Rand

ISO9001

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

04/18-Present

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

05/15-04/18

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

10/13-05/15

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

TS16949

Quality Assurance Manager

04/12-10/13

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)

5/01-04/12

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.

Accomplishments:

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

SKILLS & TECHNIQUES ACQUIRED:

Measurement System Analysis

Capability studies (Cp/Cpk analysis)

Hypothesis testing

Attribute & Variable control charts

DOE’s

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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