Quality Engineer Industrial

MICHAEL POWELL

**** ******, *******, ***** *****

Cell: 832-***-**** Email: **********@*******.***

US citizen

A hands-on individual that can think outside of the box to resolve issues seeking an opportunity to engineer and improve the Quality Engineer function or Manufacturing Engineer function in a manufacturing environment .

CAREER SUMMARY

•Managed the quality function for projects which included writing inspection/test plans, coordinated testing with customers and certifying agency surveyors, and resolving documentation issues

•Achieved ISO 9001 certification for a company

•Established procedures, work instructions, and operation setup sheets to maintain unified quality standards.

•Eliminated defects by working with suppliers

•Conducted supplier audits. (Inhouse audit training/certification at Baker Hughes and NOV)

•Experienced in casting, forging, machining, heat treating, and fabrication processes

•Determined manufacturing process routings for new parts

•Improved quality and slashed manufacturing cost by changing methods of manufacture and/or improving tooling. In some cases as much as 50%.

•Designed machining fixtures to improved machine operation setups

•Shop floor trouble shooting

•Initiated, tracked, & analyzed nonconformance reports (NCRs)

•Worked under/with the following specifications: ISO 9000, API, NDT (PT, MT, UT), AWS, ASME, ASTM

Foundry/Casting Experience: Early in my career, I was a project engineering draftsman at a large iron and steel foundry. In this position, I was involved with projects over the entire operation. In the oil tool mfg. industry as a mfg. engineer, to cut cost and improve quality, I changed many component parts from 100% machined barstock to investment castings working closely with the casting supplier. As a quality engineer, I have worked with sand casting suppliers to eliminate casting defects.

Examples of Lean Manufacturing/Continuous Improvement Accomplishments:

•One of my assignments was to convert blowout preventer bodies from sand castings to closed die forgings. I found that two BOP bodies were very similar. The two BOP bodies were identical except one had a weld neck flange welded on for a side outlet and the other did not. I designed a single forging with a simple boss on one side so that the forging could be used for either configuration. For the straight BOP body, the internal geometry and the top and bottom flanges were machined. For the BOP body with the side outlet, addition machining of skim cutting the boss surface, drilling the outlet bore, forming the seal ring groove, and drilling and tapping the bolt hole circle was done. This allowed a single forging to make two different BOP bodies saving expensive die tooling costs. Also, the integral outlet produced a stronger design eliminating the weld neck flange and welding operation, a possible source for defects.

The elimination of the flange and welding operation reduced the cost and weld shop work load.

•I was given the task to design a fixture for a milling operation for a power swivel elevator bail. I looked at the entire manufacturing process for the part and saw that a greater improvement could be made than just in one operation. The machining of the bail only represented about 1/3 of the total cost and the milling operation was the smallest portion of that. 2/3 of the cost was the raw material, a 5 1/2” thick flame cut plate 56” long which required heavy machining. Working with a forging supplier, I made an overlay drawing of the finished bail having machining stock only where needed. By converting the bail to a close die forging, the cost saving per year ($162,400) was so great that the tooling cost of $79,200 was paid back in 6 months. The change in the method of manufacture resulted in 80% of the machining cost and all heavy machining being eliminated and raw material cost was reduced. The resulting forging was a cleaner, better looking part with an embossed company logo.

CRITICAL SKILLS

Computer Skills: Microsoft Office

2D AutoCAD

Cerifications: Lean Six Sigma Green Belt (2018).

Security Clearance: Held security clearance as component engineer at U.S. Army ammunitiolastn plant

PROFESSIONAL EXPERIENCE

I realize that my employment history over the last decade looks unstable and spotty. But I am not a job hopper. I have had no control over the situation: Major reduction in force due to fall of the price of oil. Corporate closing its Houston facility and moving production to east coast facility. Unstable work environment, over a short period of time the company saw three general managers in quick secession at the whim of the owner.

Independent Quality Consultant 2/17 - Present

With the drop in the price of oil in 2015, major reductions in force occurred throughout the oil industry. Some companies continued to layoff employees over the next 5 years. I have maintained myself with menial part time work and a little short term quality consulting while job hunting.

GE OIL & GAS - HYDRIL 2/15-12/15 QA Specialist (Contract)

Reviewed and eliminated defects in Databooks for subsea BOP & related equipment before sending them to third party certifying agencies. Resolved documentation and specification issues.

PUROLATOR Advanced Filtration 4/14–11/14 Quality Engineer (Contract)

Established quality program by writing and implementing unified quality procedures and work instructions. Improved quality of suppliers, tooling, and operations. Reduced production time and cost of a multi element filter assembly operation by combining die punch operations with a single multi stage die and eliminating unnecessary operation steps.

NATIONAL OILWELL VARCO-Pressure Control Group 2011–2013 Quality Engineer

Reduced the Cost of Quality (scrap & rework) in a manufacturing environment by analyzing NCR data & wrote procedure/work instruction. Conducted special projects such as:

Working with design engineering and assembly departments in order to gain control of the fluid cleanliness issue of subsea blowout preventers’ operating fluid, wrote fluid cleanliness engineering specification and determined applicable fluid cleanliness testing equipment

THRUSTMASTER of TEXAS 2010-2011 Quality Engineer

Wrote quality work procedures, designed test equipment, facilitated documentation, and resolved quality issues. Eliminated casting defects by working with casting supplier.

OIL STATES INDUSTRIES 2005-2010 Quality Engineer

Managed quality of projects which in included writing inspect/test plans, interacting with & facilitating third party certifying surveyors (ABS & DNV GL), and resolving documentation issues. Conducted internal and external audits. Generated and followed up on NCRs. Initiated continuous improvement projects which included:

To safely, easily, & uniformly cut thick rubber packers, I designed a cutting press and supervised its manufacture.

Initiated R&D project to replaced molded rubber packers with extruded rubber packers that would reduce cost, eliminate packer order cycle time from supplier, and increase consistency in achieving dimensional requirements

In annual performance appraisals, my supervisor stated that I was “an asset to the QA Department”.

McFARLAND PUMP COMPANY 2000-2004 Quality Assurance Manager

Achieved ISO 9001 certification by writing quality documentation and training company personnel. Resolved quality problems with suppliers (machining & casting), maintained calibrated thread gauges & pressure gauges and represented company at trade shows.

EDUCATION:

University of Houston Houston, Texas

Bachelor of Science in Technology Major: Manufacturing Technology

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