Robert A. Lightsey

**** ****** ****, ******, ** 29678 adjmkb@r.postjobfree.com - 864-***-****

EDUCATION

Master of Science in Industrial Management

Clemson University, Clemson, SC

Bachelor of Science in Industrial Engineering Technology

Clemson University, Clemson, SC

Six Sigma Black Belt

Schneider Electric/Rath and Strong

Certified Quality Engineer

Certified Quality Auditor

American Society for Quality

WORK EXPERIENCE

Quality Assurance Engineer – Aerospace Structural Components

RBC Aerostructures - Westminster, SC – August 2019 – July 2020

Temporary furlough due to Covid 19 Pandemic

Primary customer is Boeing

Responsible for eliminating a backlog of hundreds of required FAIR’s

Responsible for creating process FMEA for CNC operations and preparing action plan

Responsible for QA Contract Reviews, also with large backlog

Conducted FAIR and FMEA training for inspectors and CNC operations

Quality Assurance Engineer – Aviation Ignition Systems

Champion Aerospace - Liberty, SC – March 2013 – April 2019

Responsible for Piston Engine products (Spark Plugs, Magnetos, Wire Harnesses)

Responsible for Customer Interaction, Supplier Interaction, and Internal Process Support

Warranty evaluation and responses for magnetos, wire harnesses, and spark plugs returned by customers

Provide support to problem solving teams and warranty reduction teams

Evaluate non-conforming supplier parts, solicit improvement from suppliers

Experienced with Brown and Sharpe Gage 2000 CMM and PCDMIS Software, Oasis video measurement system, numerous other gaging and measurement instruments

Identified a major field issue (timing drift) with magneto product, and facilitated the problem resolution, resulting in significant reduction in warranty costs

Responsible for identifying a serious internal manufacturing problem, also with magneto product (loose rivets), and facilitating the problem resolution

Quality Engineer – Automotive Drive Shafts

JTEKT Automotive South Carolina - January 2012 to March 2013

Responsible for APQP activities involved in the very successful launch of CV Joint Rear Drive Shaft

Primary customer Toyota

Developed QA Network, Control Plans, Process Documents, Failsafe Documents, Training Dojo, Audit and Inspection Procedures, Audit and Inspection, Gauging, etc, for CVJ Product

Developed documentation required by customer (Inspection Standard, MQC, PEP, SDS, etc) for Toyota

Participated in numerous customer and JTEKT Corporate visits

Working closely with Management to develop effective quality assurance systems

Developing systems for non-conforming material reporting and receiving inspection

Use of GQTS, GASL, Smarteam, Sharepoint

Quality Engineer – Automotive Engine Valves

U.S. Engine Valve - Westminster, SC - January 2011 to January 2012

Mentor for several Six Sigma projects

Responsible for inspection, capability studies, and documentation of new product submissions to Honda, Nissan, Toyota, and Subaru

Proficient at the use of optical comparator and mechanical gauges

Statistical experiment including Gauge R&R on sorting equipment to improve capability

Statistical experiment to reduce scrap through analysis of part tolerances and functionality

Responsible for weekly 5S audits of assigned areas

Developing systems for non-conforming material reporting and tooling forecasting

Primary customers Honda, Toyota, Nissan, Subaru

Supplier Quality Engineer – Automotive Fuel Systems

TI AUTOMOTIVE - Lavonia, GA - June 2010 to January 2011

Responsible for documenting, reporting, quarantine, and return of supplier non-conforming parts

Responsible for communicating and working with suppliers on corrective and preventive actions

Responsible for review and approval of 8D analysis submitted by suppliers

Responsible for review and approval of supplier PPAP submissions

Responsible for supplier audits

Responsible for supplier PPM reporting

Received APQP and PPAP training at Greenville Technical College

Primary customers BMW, Kia, Volkswagen

Senior Quality Assurance Engineer – Electrical Distribution Equipment

SQUARE D COMPANY - Seneca, SC - 1992 to 2000, and 2002 -2009

Active on numerous Product Development Projects and the Project Review Committees. This includes use of FMEA, DOE/Taguchi, capability studies, supplier qualification activities, etc., necessary to design quality into the product

As part of the Project Review Committees, developed database and documentation system for tracking active, completed, and proposed projects, progress reports, and management reviews

Facilitator for Defect/Cycle Time Reduction team for enclosed drive product, and Engineering Change Control Team. Provide facilitation for management meetings, product development and other process improvement team meetings

Coordinated and conducted quality training programs, including SPC and the following courses:

Competing and Winning Through Quality (Problem Solving), SMART Communications, Team Overview, Meeting Management and Group Dynamics, FMEA, DMAIC (Yellow Belt), and pre-employment training

Developed data collection and tracking systems for supplier and in-house non-conforming material and scrap, supplier corrective actions, internal ISO audit tracking, in house defect reporting and analysis, control of ISO procedure documents, customer complaints, and warranty issues, using Microsoft ACCESS

Conducted supplier audits and had an active role in developing the Supplier Management System

Conducted training sessions for suppliers

Conducted presentations for visiting executives and customers

Developed and executed training plans for product move to Mexico

Developed and implemented facility wide Training initiative. Training initiative resulted in a 48% reduction in fabricated part forming errors, 30% reduction in Assembly errors, and 20% reduction in Engineering drawing errors

Implemented new intranet based system for ISO9001 Document Control and Corrective Action Requests.

Implemented the Customer Complaint Response system

Conducted and mentored numerous Six Sigma Black Belt projects, resulting in significant reduction in warranty charges and improved customer satisfaction

Start Up Yield Manager, Developed and implemented data collection and analysis systems for Start Up Yield improvement program

Facilitated plant wide process map development and process improvement steering committee. Includes development of plant process map, computer simulation models, identification of information needs and process improvement projects for the entire facility, to be used in developing an integrated manufacturing system

Active part of implementation and maintenance of quality system and procedures registered under ISO 9001

Product Quality Engineer - Automotive Transfer Cases for SUV's

BORG WARNER AUTOMOTIVE - Seneca, SC - 2001 to 2002

Responsible for Quality of Mercedes Benz and Isuzu products

Conducted joint audit of a supplier with a representative from Mercedes

Conducted sorts of suspect product before shipment to Mercedes

Worked with supplier of castings to reduce porosity issues

Submitted PPAP documents to customers

Quality Assurance Manager -Pneumatic Actuators

COMPACT AUTOMATION PRODUCTS - Westminster, SC - 2000 to 2001

Managed department of 5 Inspectors, Returns Analyst, Mfg. Engineering, Document Control

Managed re-structuring during plant downsizing during economic downturn

Implemented ISO Document System, introduced FMEA, capability studies, etc., into the quality system

Involved in implementing Oracle ERP System

Assistant Plant Manager - Diamond Abrasive Cutting Tools

ERNST WINTER & SON, INC - 1990 to 1992

Implemented SPC program

Supervised production planning and control

Performed all Industrial Engineering functions

Industrial/Project Engineer- Twist Drill Bits

GREENFIELD INDUSTRIES - Clemson, SC - 1988 to 1990

Implemented an automated networked SPC system

Conducted SPC training, customer visits, and supplier certification

Performed all Industrial Engineering functions, including researching and justifying capital for new packaging machine

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Entry Level and Developmental Assignments (5 years) -- Experience in Industrial Engineering in Textiles: work measurement and setting piece rates, labor budget, cost estimation, new equipment justification and layout, job design, payroll, and worked with MRP system. Co-designed a new pillowcase folding and stacking machine.

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