Quality Manager Injection Molding

GARY R. BULLOCK

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

952-***-**** cell / ***********@*****.***

CAREER OBJECTIVE: The opportunity to become team member of a progressive company; utilizing experience in Quality Systems, AIAG core quality tools SPC and in-depth knowledge of Safety, Quality, and Environmental Management Systems in a manufacturing and business environment. I would appreciate the opportunity to advance and grow as a Quality Professional in which I can become a contributing team member of a progressive team in a thriving company that provides opportunities and cares about each employee.

PROFESSIONAL PROFILE:

•20+ years Quality Assurance experience in a manufacturing environment

•10+ years Quality Assurance experience in Automotive supplier manufacturing

•Experienced Quality Manager with extensive responsibility and success of the Advanced Product Quality programs

•QMS and EMS Management experience in ISO 9001-2000, ISO 9001: 2008, ISO 14001:2004, TS 16949 as a Quality Manager and auditor, CQI-9 auditor, CQI-23 auditor, VDA6.3 (Volkswagen/European Automotive) audits, Quality Engineer and Lead Auditor, Certified Quality Auditor and Senior ASQ member.

•Manufacturing and injection molding experience: Quality Assurance, Environmental, and Safety.

•Designed, installed and received certification for two systems (Environmental ISO 14001:2009 and ISO 9001:2000 Quality) within eleven months (2008).

•Systex Products Arkansas Company recognized as top five finalists by Arkansas Department of Environmental Quality for 2009 Envy of Arkansas Environmental Stewardship Award.

•Continuous Improvement project; Scrap reduction which equaled $1000.00 per day savings by improving pre-paint part preparation.

•Red X problem solving

•Continuous Improvement project experience, KAIZEN

Certifications

•ASQ Certified Quality Auditor Certificate #29601

•Certified Lead Auditor ISO 9001: 2008 TS16949 Omnex Engineering & Management, Inc. Certificate # 6843 March 2013

•Lead Auditor ISO 9001-2000 – BSI Management Systems / Certificate # 448****-*****

•Lead Auditor ISO 9001- 2000 TS16949 Automotive Standard / PIC group Certificate # 04172

•Internal Auditor ISO 9001:2015

Skills / Experience

•10 Plus Years’ In Metal Working

•14 Years in Plastics.

•In Plant Receiving Inspection Quality

•Vendor Offsite Supplier Quality

•Tooling Quality

•Quality Database Systems

•Creating SOP Training

•Quality Management Experience

•Quality Training Experience

•Internal Quality system audits

•External Quality system audits

•Setting Up Quality Systems

•Using CMM Equipment

•Statistical Investigations

•Investigating Customer Complaints

•Analyzing Production Limitations

•DFMEA, PFEMA

•GD&T

•8D – root cause, corrective action

•Implementing Corrective Actions

•OEM Manufacturing

•ISO 9001:2008, ISO 9001:2015

•IATF 16949

•ISO 14001:2004

•Leading Kaizen Events

•Performing Kanban

•Implementing Continuous improvement

•Designing Process Improvement Trials

•Generating Process Control Charts

•Process Flow sheeting

•Product Reject / Defect Investigations

•Recommending Specification Revisions

•Reducing Scrap

•Implementing Corrective Action

•Non Destructive Testing

•First Article Inspection FAI

•Tracking Yield Metrics

•Tracking Throughput Metrics

•Improving Operations Effectiveness

•Using Labor Metrics

•Improving Change Order Cycle Time

•Assembly Operations

•Machining Operations

•Heat Treat Operations

•Painting Operations

•Injection Molding Operations

•PPAP

•APQP

•PPM Reduction

•Coordinating Lab Activities

Professional Accomplishments:

Franklin Electric- Implemented Layered Process Audits, converted inspection documents and audits from paper to digital using MS forms and iPads.

YFAI- Scrap cost reduction through process improvement- reduction from $5000 per week to $500.

This was accomplished via KAZEN project. (Paint Process)

Design/install received certification for ISO 9001:2000 and ISO 14001 within 11 months 2008 (Systex Products).

Systex Products received Environmental Award from the state of Arkansas April 2009 for Environmental Management System; reduction of waste stream by 5,000 pounds per month to less than 2,000 per year and increased recycling.

The Naked Truth Training and Empowerment Center received Environmental Award from the state of Arkansas for environmental education and recycling program April 2010.

GM Supplier Excellence Award 2013 NSK Corporation / GM Supplier Excellence Award October 2014 NSK Corporation

Franklin Electric 11/04/2019- 05/20/2022

Regional Quality Manager

The primary products for these facilities are submersible electric pumps and motors, pump trailer packages that are used to move water on job sites. Pioneer Trailer Packages

Responsible for 3 facilities- Product Quality, Supplier Quality, Cost of Poor Quality, ISO 9001:2015 Quality Systems.

Managed and support staff- Quality Manager, Quality Supervisor, 9 Quality Technicians

Root cause investigation and Corrective and Preventive action implementation using the 8D process via the software INTELEX

Mentor cross functional focusing process improvement and scrap cost reduction

Monthly report out to Global Leadership using KPI scorecard including action item list.

Martinrea International 08/2018- 11/2019

Senior Quality Engineer/ Assistant Quality Manager

This facility is a Tier 1 supplier to GM assembling chassis for the Malibu and Cadillac SUV. John Deere was industrial customer for fender supports used on farming equipment.

Responsible for scrap cost reduction, customer complaints, supplier development, QMS (Quality Management System) IATF 16949 automotive standard

Worked closely with GM and John Deere customer representative

Implemented LPA (Layered Process Audit) system

PPAP creation and completion

Responsible for IATF internal audits and follow up action items

Received and accepted offer from Franklin Electric

Syncreon 09/05/17- 05/2018

Quality Manager

•This position requires experience with ISO 9001:2015, supplier requirements as directed by Harley Davidson and experience with core tools, including Quality Planning, Control Plans, Failure Mode and Effect Analysis, Problem Solving tools such as 8D, 5 why, Fishbone and Corrective Action Reports.

•I lead and manage and mentor a team of 2 Quality Engineers, 1 Quality Supervisor, 8 Quality Technicians and 4 Quality Auditors

•Our team works together to reduce scrap cost, eliminate waste and customer complaints

•I work with the Continuous Improvement Corporate Manager planning and scheduling Kaizen projects

•My team and I prepare KPI reports for our customer and corporate leadership. I present these reports weekly via phone conference or in person.

•We build the subassembly components for Harley Davidson motorcycles and provide logistical support for Harley Davidson by providing warehouse services and receiving and shipping. I have responsibility for two facilities; manufacturing facility and a warehouse.

•Harley Davidson made the decision to close the Kansas City, MO facility

YFAI 01/29/2016 – 09/02/17

Senior Quality Engineer / Continuous Improvement Engineer

•This position required experience with TS16949 and familiarity with AIAG supplier requirements and experience with core tools, including Advanced Product Quality Planning, Production Part Approval Process, Control Plans, Failure Mode and Effect Analysis and SPC.

•I work with and mentor a team of 7 Quality Engineers, 12 Quality Technicians as Tier One suppliers to GM.

•My team and I work to; develop and improve suppliers, reduce scrap, address customer complaints and drive improvements by listening to the voice of the customer.

•I am on the audit team which conducts audits (locally and at other facilities) on the; BOS (Business Operating System) and preparation for TS16949 certification

•We worked as cohesive unit to drive process improvements as related to product quality, safety and supplier quality. I work on the Continuous Improvement team for our facility; we identify processes that need improvement, thus conduct C.I events and develop improvement projects.

•This facility’s processes included molding, paint and assembly for cockpits, door panels and consoles for GM specifically Malibu and the Colorado truck.

•Position eliminated due business climate: Malibu sales required downsizing at YFAI, thus layoff

Thermotech LLC 01/2015-10/2015

Quality Manager

•This position required experience with TS16949 and familiarity with AIAG supplier requirements and experience with core tools, including Advanced Product Quality Planning, Production Part Approval Process, Control Plans, Failure Mode and Effect Analysis and SPC.

•I managed a team of 2 Quality Engineers, 3 Quality Technicians, 1 Quality Supervisor, 10 Quality Auditors.

•Responsible for the following: KPI’s Customer score cards, Supplier Development, Defective Material inventory level, QMS (TS16949), Auditing System (CQI-23, CQI-9, VDA 6.3) and Process improvements as related to product quality.

• This is a customer molding facility with the largest percentage of customers being automotive.

•Company was purchased and my position eliminated. I left with severance

NSK Corporation Bearing Division 07/12 – 01/2015

Quality Manager

•The primary product for this facility is precision bearings used in the automotive market and commercial applications

•Developed vision and quality policy for this facility Quality Management System maintenance,(TS16949),

•Audit Coordinator; Lead internal audits, LPA ( Layered Process Audit),CQI-9 heat treat audits, Internal Audits and Corrective action process, Customer relations and KPI reporting:

•Customer complaints, Cost of Poor Quality and Improvement, Supplier Development,

•Manage Quality staff: 16 team members;3 Quality Engineers, 2 quality specialists, 2 gage technicians, 9 Quality Technicians, 9 contract team members for a 3 shift operation and 400 employees within the entire operation

•QMS Management Representative ISO 9001:2008, TS16949

•Recruited to Thermotech

Systex Products Company Arkansas 09/07 – 01/12

Quality Supervisor/EMS, QMS

•Representative Injection Molding Automotive Supplier

•Designed and implemented the Environmental Management system; develop new system for ISO 14001: 2004.

•Create procedures and environmental process for the EMS.

•Maintain Internal Audit systems for EMS and QMS and then report results in Management review meetings.

•The AIAG supplier requirements and experience with core tools, including Advanced Product Quality Planning, Production Part Approval Process, Control Plans, Failure Mode and Effect Analysis and SPC were required in this position.

•Design and create QMS for ISO 9001:2000, ISO 9001:2008,

•Customer service liaison: answer customer complaints

•Aid in the effective corrective and preventive action.

•Responsible for management of QMS and EMS, (staff of 4 Quality Auditors) assists in the training of new associates as related Quality Assurance, Environmental, Health and Safety.

•Conduct monthly Safety Audits, report results to upper management. Develop Safety programs and create Safety procedures.

•This is a Japanese owned company that focuses on automotive components. The primary customers are DENSO and Toyota.

•My dad has Parkinson’s and I took time off to be with him until he was stable and able to take care of himself.

Century Mold 06/06 – 07/07

Quality Engineer Injection Molding

Automotive Supplier

•Develop Control Plans, PFEMA, APQP, MSA, and Process Maps,

•Conduct Internal Audits and assist in maintaining Internal Audit system Customer service liaison:

•Answer customer complaints aid in the effective corrective and preventive actions.

•Design and develop gages and methods of inspection.

•Disposition non-conforming material; review and direct quality inspectors in the disposition of this material.

•Perform dimensional layouts, capability studies;

•Prepare PPAP packages as per customer requirements.

•Recession hit and I was laid off.

Atlantis Plastics / TN 11/04 – 06/06

Quality Assurance Manager Injection Molding Automotive Supplier

•Quality Management system; convert and develop new system from QS9000 to TS16949 which the facility received certification.

•Develop Control Plans, PFEMA, APQP, MSA, and Process Maps,

•Train Internal Auditors.

•Maintain Internal Audit system and then report results in Management review meetings.

•Customer service liaison: answer customer complaints aid in the effective corrective and preventive action.

•Train new associates as related to Safety and Quality Assurance;

•Maintain Safety Records (OSHA 300 log).

•The product mix was primarily automotive as the customer base. Customers: Mahle and other automotive component suppliers.

•Company in distress and went bankrupt.

Ecowater Systems, MS 03/03 – 10/04

Quality Assurance Engineer/Assistant Quality Manager

Injection Molding, Blow Molding

•Responsibilities include Training, maintain, and create work instructions, Gage design, Customer service, Supplier Auditor, Internal Auditor, and Assistant Quality Manager,

•New product design as related to Quality functions: Print revisions, Quality Control Plans,

•Conduct: PPAP’s, Capability Studies, Gage R&R, Tool Qualifications, PFEMA and PPM Reporting.

•The product mix was water softeners, reverse osmosis water filters and whole house water (sump) water filters.

•Recruited to Atlantis

Spartech Industries Injection Molding and Extrusion 11/01- 01/03

Quality Manager/ Management Representative ISO 9001-2000

•The primary responsibilities include Quality System management, Safety, Training, maintain and create work instructions, gage design, Customer service, Supplier Auditor.

•Provide support with PPAPs’, Capability Studies, Gage R&R, Tool Qualifications, PFEMAs’ and the cost of poor quality.

•The primary customer was MTD with focus on lawn and garden equipment with the other product mix was commercial applications.

•Small Startup Company and I left to grow my career.

EDUCATION:

•BSBA / Colorado Christian University 2011- / Completion 2023 completing final 9 credit hours for degree

•University of Phoenix attended 2005 - 2007

•BSBM Management / Itawamba Community College attended 2004

•Industrial Technology / Itawamba Community College attended 1986 - 1987

•Tool and Die Certification / Itawamba Community College 1979 - 1981

ADDITIONAL PROFESSIONAL TRAINING AND EDUCATION:

•Statistical Process Control (SPC) - Tecumseh Products

•GD&T - Tecumseh Products

•Research and Development - Tecumseh Products, Supervision and Management - Northeast Community College

•Certified Internal Auditor ISO 9001- 2000 -Spartech Industries

•Certified Internal Auditor ISO 14001-1996 Spartech Industries

•Mississippi Manufacturing Association Quality Board Examiner 2002

•Paulson Injection Molding Training- Spartech Industries

•Community Leadership Institute-Community Development Foundation Class of 2004

•Certified Internal Auditor ISO 14001-2004 Systex Products

•Computer skills: Excel, MS Word, PowerPoint CA5 (Corrective Action software), Minitab (Statistical software) Gagetrak (Gage Calibration Software), INTELEX customer complaint and audit software

•Lean Manufacturing – Ecowater Systems

•Leadership: 7 Habits of Highly Successful People (Systex Products)

•RESNET: HERS Rater (Energy Rater) Pulaski Technical College April 11, 2011

•Red X Problem Solving (Apprentice Training) GM Fairfax, KS March 2016

•Lead Leadership Institute for high potential managers November 2013

•Supervision for success; Leadership YFAI Riverside, MO January 2017

•Lead Auditor transition TS16949 TO IATF 16949 June 2017

• 6 Sigma Green Belt – completion August 2022,

• 6 Sigma Black Belt completion January 2023

Contact this candidate