Quality Engineer Manager

MARLIN L. DARNEL

Union, Kentucky

419-***-**** Mobile

********@*****.***

PROFESSIONAL SUMMARY

Degreed professional with ASQ, GM, AIAG and AES training; including Quality Management, Quality Engineering, Statistical Design of Experiments, and GM Statistical Engineering Red X techniques.

Coordinated successful implementation of ISO9000 through IATF16949:2016 and AS9100 certification for duct/seating products in automotive, commercial products, defense and aerospace component applications.

Led international supplier and domestic product launches within Safran, Ford and GM quality program guidelines.

Industrial background includes heat treat, metal fabrication and welding processes; including stamping, forming, load testing, laser cutting, bending, brazing, soldering, CNC, robotic, resistance and MIG welding.

Quality and process familiarity with instrument and electronic control components, New Product Development, GOCO processes, capacitor, composite, thermoset and thermoplastic molding; including blow molding, extrusion molding, transfer and compression molding, injection molding, painting, sonic welding, mistake proof, clean room testing, GMP, ESD and safety requirements, robotics assembly and manufacturing, electro-mechanical, OEM component assembly and NDT Inspection.

Knowledgeable of current industrial process, safety, ergonomic and environmental requirements.

Familiar with systems support to GE, Boeing, Airbus, SAFRAN and Airbus Engines, Allied Signal, Honeywell, Lockheed Martin, Rockwell Aerospace, Parker Hannifin, General Dynamics, Fram, Purolator, Hearth & Home, GM, Ford, BMW, FCA, Toyota, PACCAR, Mercedes, Nissan, Volkswagen, Honda, and Hyundai.

Gauging and test equipment: FARO & CMM Analysis, Contracer, Hardness, Polymer Testing, Pressure, Load Testing

Training and application of internal process audits for ISO 9001, AS9100, IATF16949 and ISO 14001.

Employed DOE, FMEA, FTA Analysis, MTTF, IPC JSTD-001 Standard, Shainin Red X, Kaizen, Lean 6 Sigma, 8D, 5 Why, GMP, 3P/Rapid Continuous/Ergonomic Improvement, DPRV, 5S/6S, GMS, VSM, GD&T, TPS and DMAIC.

Utilized Cognos, SAP, Axalant, Mini Tab, Gagetrak, MPact, data analysis and project management applications.

EMPLOYMENT

Quality Manager, SAF HOLLAND INC., Cincinnati, OH, December 2019 to May 2020

Directed the site manufacturing quality assurance function for a major trucking components company.

Led internal, supplier and customer quality response and corrective actions for fifth wheel truck components.

Guided tool/process calibration, plant QRQC, 5Why/1H problem resolution, and process/continuous improvement.

Site EHS manager for the company manufacturing process, leading safety audits, training and floor 5S activities.

Lowered PACCAR CAR response time by 80%, and took SAF Holland off the PACCAR B25 troubled supplier list.

Supplier Quality Engineer, SAFRAN AEROSPACE, Sharonville, OH, Oct.2018 to Oct. 2019

Supported Safran engine component suppliers during multi platform component launches and quality events for Leap 1A and Leap 1B OEM engine programs.

Coordinated OEM and MRO supplier quality audits and system reviews with corporate Supplier Quality Engineers.

Conducted Process, Product, Clean Room, Soldering and Theme based audits to Safran Supplier Quality Management requirements, coordinating supplier compliance and corrective actions.

Guided supplier DVI and quality improvement activities; including FAI, 8D, 5Why and 3M disciplines.

Led cross-functional Web-Ex calls; with supplier and corporate management, quality, engineering, industrialization and logistics representatives.

Guided a composite component supplier Meggitt during successful special process audit in compliance with SAFRAN supplier quality requirements, as they completed Leap 1A DVI stages and launch activities.

Supported multiple Tier II aerospace component and special process Leap 1B supplier DVIs with two separate GE Aviation SAFRAN supplier sites.

Supplier Launch Q. Engr, (Contract with EPITEC, Southfield, MI), Ford Transmission, Sharonville, OH, Feb.2018 to Aug. 2018

Guided Ford Transmission suppliers during multi-phase launch activities for the current Ford 10R140 program.

Evaluated supplier quality and production systems, mechanical and contamination labs, gauging, testing capacity and technical competency, ensuring supplied products to be in compliance with Ford Transmission directives.

Audited international approved supplier quality and test systems against control plans, Safe Launch requirements, and PFMEA failure modes, based on Ford warranty issues and surrogate system Lessons Learned results.

Coordinated third party dimensional inspection verification, and reviewed supplier PPAPs for approval.

Supported a FORD Transmission plastics supplier during oil pan component launch activities and PPAP approval.

Quality Supervisor/Engineer, MUBEA TRANSMISSION SPRINGS, Florence, KY, April 2013 to September 2017

Supported quality processes in a major international Tier 1 automotive transmission springs facility, with $60 M in annual sales, in coil steel Fine Blanking, part deburring, forming, shot peening, and spring load testing.

Responsible for shift QA technician teams, CMM and calibration technicians, while working with the plant Quality Engineers, supporting APQP and PPAP activities, while monitoring site statistical and physical testing. Led containment and MRB activities for supplier/internal and customer quality issues, driving corrective action, and reduction of open supplier quality issues by 34 percent, for a 40 percent increase in product launches in 4 years.

Successfully led supplier and internal problem resolution activities, with the launching of a spring rust preventative program, including the addition of rust preventative additives, and verified by titration process control so customer rust complaints improved by 30% within two years.

Supplier Quality Engineer, ZF STEERING SYSTEMS, Florence, KY, September 2011 to February 2013

Provided quality support and management development to international suppliers for a leading automotive steering systems company with $900 million in annual sales. Performed process and control plan audits verifying system improvements, APQP activities, gage and process implementations, and new equipment purchases.

Led three plastics and rubber component suppliers through problem resolution, and improved customer failures in two years by implementing quality and processing steps to prevent internal scrap and processing costs.

Quality Engineer/Analyst, HEARTH&HOME TECH., Lake City, MN, December 2008 to April 2010

Facilitated quality engineering activities for a leading international gas fireplace and consumer products plant, with $80 million annual sales. Reviewed monthly quality cost/warranty trends, through Cognos database and statistical analysis. Trained in Rapid Continuous Improvement and Kaizen activities, using Seven Flows, 4 M’s and the Nakao method, leading to a 32% reduction of the process footprint and cycle times.

Led continuous improvement activities lowering heat transfer processing costs in supplied gas fireplace components

Contract Supplier Q. Engr., (PROCESS DEVEL. CORP., Livonia, MI), to General Motors, Warren, MI, July 2006 to May 2008

Provided GM Purchasing supplier support through periodic CS and QMS audits and staff development during a 26 week QSB development period, toward graduation of suppliers from the Top Focus level. Trained international supplier staff on 5 Why problem resolution (Drill Deep), while leveraging results across similar process with multiple suppliers (Drill Wide).

Led multiple suppliers through graduation from the GM Top Focus level of problem suppliers.

Led supplier launch activities for Tier II suppliers to a Korean Tier I supplier to GM in Mexico for providing internal plastic body components for the 2008 Saturn Vue.

Quality Engineer, LEAR CORPORATION, Fremont, OH, September 2001 to January 2005

Facilitated quality engineering activities on key programs for a major TS-16949 certified international automotive blow mold/injection molding supplier, with $40 million annual sales. Provided MPACT and PFMEA support, and coordinated multiple product launches, with successful APQP development and PPAPs for OEM/Tier 1 customers.

Quality Manager - Facilitator, DEFIANCE PRECISION PRODUCTS, Upper Sandusky, OH, March 2000 to July 2001

Directed all Quality Assurance activities, prepared departmental budgets for a QS9000 certified Tier 2 automotive bearing manufacturing plant, with annual sales of $20 million.

Developed control systems and qualified a new product line Flexible Machine Cell supporting a 40% increase in annual sales.

PROFESSIONAL TRAINING / CERTIFICATION

PACCAR EPIC Process Improvement Training 2020

AS9100 Product Process Audit Training 2019

ISO IATF16949 Transition Training 2016

Ford Minitab 6 Sigma Process Improvement Training 2015

AIAG Design and Process FMEA with APQP Training 2015, 2011

RCI, 3P and Kaizen Improvement Training 2009, 2010, 2012

GM Statistical Engineering Red X Training – Apprentice Level 2007

AES Certified ISO9000 Internal Auditor Training 1998

ASQ Certified Quality Manager Refresher Training 1997

ASQ Certified Quality Engineer 1986 – 1989

EDUCATION

UNIVERSITY of NEBRASKA at KEARNEY, BA in Education, Kearney, NE

Postgraduate work in calculus and statistics

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