Quality Engineering Management

TOM CALLINAN

Katy, Texas ***** Cell: 832-***-**** E-mail: ********@*****.***

Quality System Design Quality Assurance Quality Control Safety Reliability ISO9001, AS9100, API, Q1, Q2 certified, results-driven leader of cross-functional teams in the fields of quality, reliability, and manufacturing. Forty plus years of continuous improvement, lean manufacturing, system design, safety and reliability analyses in the electronics, aerospace, & oil and gas industries. PROFESSIONAL EXPERIENCE

Dril-Quip, Inc., Houston, Texas

Quality Control Manager Feb 2019 - Apr 2020

• Managed day to day activities of 68 Quality Control inspectors including Dimensional, NDE, UT, PT, MP II, X-Ray, ACCP CWI, LP, Gages, Receiving/Shipping, Calibration Lab, Source Inspection, Assembly, and Coating

• Developed, implemented, and enforced quality procedures designed to ensure that quality flaws in design, materials and workmanship have been identified and corrected before products are released for shipment

• Implemented quality policies and procedures, inspection test plans, and completed traceability inspection forms to assure customer and industry quality requirements were met

• Directed the quality control activities required for the manufacture of equipment in accordance with the company’s ISO 9001:2015, API Q1/Q2 and DQ Quality Management System (QMS)

• Tracked KPI performance indicators, identified deficiencies & worked personnel improving performance/efficiency

• Responsible for overseeing the Mechanical Test Lab and Maintained ISO 17025 certification for tensile, Rockwell hardness, Charpy impact, and CTOD testing

• Managed calibration system for recertification of company and individual employee inspection tools and gauges

• Scheduled workflow through Quality control per internal scheduling system

• Developed and maintained training program with qualification and certification records of all personnel

• Increased area capabilities and capacities in an economical manner

• Implemented Lean / 5S in QC areas, while equipping and involving personnel during projects

• Prepared reports and other work documents in a timely and accurate manner ensuring traceability of products

• Ensured adherence to industrial safety and health guidelines by understanding and utilizing safe work practices

• Supported Advanced Product Quality Planning (APQP) initiatives as required

• Reviewed inspection data; managed and resolved non-conforming reports

• Advised department managers, including Quality Assurance, of actions required to prevent problems from repeating

• Implemented Lean concepts, including 5S to streamline and increase efficiency of manufacturing process Quality Assurance Manager Jan 2015 - Feb 2019

• Managed the Quality Assurance functions including Quality Engineering, Inspection, Supply Chain Management, Configuration/Data Management, Advanced Product Quality Planning (APQP)

• Excelled in failure analysis RCFA problem solving Methodologies using 8D, fishbone, & 5 Why

• Implemented the Integrated Product Team (IPT) concept using process improvement tools (DMAIC, FMEA, Kaizen, Value Stream mapping) to reduce scrap and rework cost

• Developed non-existing NCR dashboards improving visibility of NCRs for trending and use during the IPTs

• Implemented an Electronic EDW process and Inspection Reconditioning Reports (IRRs)

• Cut Quality Records resources in half while dramatically improving on-time delivery and quality of databooks

• Created electronic forms team to improve the databook process

• Developed and implemented the Third Party Inspection electronic databook review process eliminating printed books

• Managed the Quality implementation of the APQP process for BP products

• Completed SOS (safety observation and suggestion card) in compliance with current QHSE guidelines TOM CALLINAN

Katy, Texas 77449 Cell: 832-***-**** E-mail: ********@*****.***

• Implemented a Sales Order review process for Inter Company POs improving the deliverables

• Planned, lead and executed company quality systems and activities ensuring conformance to industry requirements

• Managed the Quality section for RFQs for all new products and customers

• Implemented Quality Lunch and Learns for the Quality team including use of the Gemba Academy training videos

• Introduced the Field Problem Report trending charts allowing resources to focus on Service issues

• Improved quality assurance programs/personnel in meeting or exceeding ISO9001, API, Q1, & Q2 systems compliance

• Monitored/Reported quality assurance KPI's to management and implemented continuous improvement plans

• Developed and maintained department budget. Revised/improved the Quality section of new employee On-boarding

• Supported Gage R&Rs reducing the variability of measurement including managing the improvement of the CMM

• Managed company AVL, Vendor NCR's, vendor corrective actions and vendor audits

• CPAR process document continuous improvements to improve our ability to detect failures in house between IPTs

• Supported receiving inspection process to ensure vendor KPI's are being measured and Process Control Plans are being developed and followed for receiving inspection activities

• Supported project, documentation, and requirements teams. Managed inspection and test plans, project quality plans, manufacturing work instructions, process control plans for internal and external products

• Interfaced with Engineering, Sales, Aftermarket, Project Management, Service, Supply Chain and Operations to ensure products and process quality assurance was transferred to production for new and existing products

• Developed employees through personal coaching and mentoring, evaluated through performance reviews

• Identified training needs for quality assurance team, including methods for problems solving and tools and methods

• Managed quality records/databook group

• Supported QC operations and inspectors

Oceaneering International, Inc., Houston, Texas 2008 - 2014 Product Assurance Manager

• Managed the Oceaneering Product Assurance functions including Quality Engineering, Inspection, Supply Chain Management, Configuration/Data Management, System Safety, Reliability & Maintainability Engineering

• Coordinated Product Assurance (PA) activities with multiple organizations throughout the company ensuring products and services are on-time and in-budget, including Acceptance Data Books, while satisfying internal and external customer specifications

• Management Rep that produced and facilitated the execution and maintenance of records ensuring the ISO 9001, 2008 and AS9100 Rev C Quality Management System remains certified

• KPIs: On-time delivery – hardware 99%, data 97%. Job Profit –exceeded margins on 97% of all projects. Total Customer satisfaction rating 5.5 out of 6.0. Passed 2013 & 2014 ISO9001 & AS9100 external audit certification with zero findings and zero observations

• Responsible for supplier quality, vendor/supplier audits & source inspections ensuring consistently meet requirements

• Managed resources to implement, monitor, review, and approve engineering and manufacturing documentation ensuring resources are allocated to maintain the engineering and manufacturing document change control system

• Reviewed and approved Acceptance Data Packages, ensuring 100% compliance to customer requirements

• Developed company key process indicators (KPI), and performed trending analysis ensuring continuous improvement

• Approved Project Plans focusing on critical to quality (CTQ) & critical to process (CTP) indicators for product life cycle

• Developed and managed the Cost of Poor Quality (COPQ) process with a 40% reduction goal

• Established and managed inspectors work priorities and certifications, while supporting project and company goals

• Coordinated issue resolutions, reducing interruptions allowing inspectors to focus on performing their inspection duties therefore reducing inspection time and cost by 15% TOM CALLINAN

Katy, Texas 77449 Cell: 832-***-**** E-mail: ********@*****.***

• Implemented Receiving Inspection problem tracking system and a vendor rating system improving vendor discrepancy tracking and reducing purchase order corrections allowing the supply chain to improve on-time and quality with actionable and accurate data

• Developed and implemented supplier process validation tools, and reliability testing methods

• Developed and maintained a gage calibration system that also tracked where used

• Produced Subsea hardware to the American Petroleum Institute (API) quality standard United Space Alliance (USA),Houston, Texas 2004 - 2008 Quality Lead, Constellation Program and Orbiter Element - Safety, Reliability & Quality Assurance

• Hired, managed, supervised, evaluated, and trained employees in Quality functions including: root cause analysis, failure reporting, corrective/preventive action plan, and process improvement

• Produced process capability studies (Cpk) for critical vendors including Boeing for the development of BRI-18 heat shield tile for the Space Shuttle

• Responsible for supervising Quality Engineering personnel throughout the Constellation Program Office

• Developed and refined requirements and procurement documents/specifications, statements of work, and schedules

• Produced/Presented multiple quality process indicators/reports/charts (monthly/quarterly) for executive management

• Evaluated Hazard Reports, Failure Modes and Effects Analysis (FMEA)/Critical Items List (CIL) for safety

• Co-authored the Quality Plan for the Constellation Orion Project with Lockheed Martin

• Co-authored the USA Constellation Program Quality Plan

• Point of contact for AS 9100, ISO 9001 & ISO 14001 audits, ensuring compliance and certification

• Lead the USA Quality Review Panel, establishing USA’s product quality index (PQI) for trending & data analysis Geologics, Houston, Texas 2002 - 2004

Reliability Engineer (Contracted to United Space Alliance SQ&MA)

• Developed reliability system/software architecture using Excel and Access for documenting FMEAs/CILs

• Generated component and system level Failure Modes & Effect Analysis

• Member of the Thermal and Vibration Requirements, Test, and Analyses engineering review team

• Produced/Verified the Avionics change request list to ensure safe return to flight of the Aging Vehicle Analysis team SKILLS

Certifications:ISO9001, AS9100, API Q1/Q2, Malcolm Baldrige, Black Belt Six Sigma, Trainer (TQM, DFMA, DOE) Software:Excel, Word, PowerPoint,SQL,Crystal Reports, Data Processing System Avionics, Gage R&R, Minitab Measurement System Analysis

Reliability and Risk Analysis: Failure Modes Effects Analysis (FMEA), Critical Item List (CILS), PCASS, PRACA, Environmental Stress Screening (ESS), PFMEA, DFMEA, Tap Root Analysis, Hazard analyses, 8D, 5 why, fishbone Manufacturing:Lean Manufacturing, Design reviews, COPQ, 5S, APQP, ITP, Quality Plans, Warranty Management Quality:Total Quality Management (TQM), Statistical Process Control (SPC), Product Improvement Team (PIT), Quality Leadership Team (QLT), Out-of-Box Failure (OBF), Closed Loop Corrective Action, Early Detection Quality Program Experienced in Basis of Estimate (BOE), Statements of Work (SOW), and Request for Proposal (RFQ) EDUCATION

University of Houston, Houston, TX, Electrical Engineering United Electronics Institute, Tampa, FL, Top Honor Graduate Columbus College, Rothschild Academic Scholarship

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