Quality Engineer Manager
Resume:
Keith A. Starr
Evans, GA ***09
(H)706-***-****
(M)803-***-****
********@*****.***
CAREER SUMMARY
Quality and Reliability Engineering professional, with more than 20 years experience in Quality and Supply Chain Management. Developed Global Quality Systems, Process Improvement and Customer Satisfaction metrics using Six Sigma and Lean disciplines in a high technology manufacturing environment. A proven motivator and mentor of engineering and support personnel worldwide demonstrating complete attention to detail and the ability to meet exact specifications within quality cost and time objectives. Certified Lead Auditor for ISO 9000-2015 and NQA-1. Experienced Black Belt in both Six Sigma and Lean methodology.
SUMMARY OF QUALIFICATIONS
Experienced Six Sigma and Lean Black Belt
Development and implementation of the Quality Management System
PFMEA/Control Plan/PPAP, SPC, SAP, 5S, Lean Mfg, Six Sigma
Knowledge of industry standards – ISO 9001, ISO 14001, NQA-1, QS9000, TS16949, TL9000,
Customer Quality/Supplier Quality Professional
8D Problem Solving & Decision-Making Mentor
Lead Auditor for both internal assessment and for Supplier Development
IPC-610D, 600, J-STD-011D, J-STD-033
PROFESSIONAL EXPERIENCE
Starr PV, Evans, GA
QUALITY MANAGER, 2021-Present
Experienced Lead Auditor ISO, Nuclear Quality Assurance (NQA-1), TL, AS, TS/QS Standards. Certified Nuclear Lead Auditor. Certified ISO 9001-2015 Lead Auditor.
Successfully implemented the Corporate QMS at specific sites based on customer requirements ranging from ISO compliant to ISO certified.
Rexel, Augusta, GA
REGIONAL SENIOR QUALITY ENGINEER, 2011-2021
Experienced Lead Auditor ISO, Nuclear Quality Assurance (NQA-1), TL, AS, TS/QS Standards. Certified Nuclear Lead Auditor including 10CFR50 Appendix B, ASME NQA-1 and ANSI N45.2.23 training. Certified ISO 9001-2015 Lead Auditor.
Successfully implemented the Corporate QMS at specific sites based on customer requirements ranging from ISO compliant to ISO certified.
Experienced Quality Leader for ITAR and DFARS implementation and operations.
Direct customer facing support of new project and opportunities which resulted in over $30MM in increased revenue annually for customers requiring a QMS in place.
Experienced Leader focused on Lean Six-Sigma and Lean Supply Chain methodologies.
Created the lean vision, provide overall lean leadership and implement the lean strategy with key customers to reduce inventory, lead-time and waste to specific value streams.
Mapped business processes, gather Voice of Customer, identify Critical to Quality characteristics (CTQs) and establish metrics; lead cross-functional project teams and use DMAIC, LEAN and Kaizen techniques for process improvement and simplification.
Implemented Lean Manufacturing initiatives throughout the facility and into the supply base.
Provide direction, training and leadership for Management and Engineers at all levels.
Flextronics, West Columbia, SC
SENIOR SUPPLIER QUALITY ENGINEER, 2008-2011
Developed and implemented Globally:
oSQE Best Practices Globally
oAchieved the highest Customer Satisfaction ratings for Quality and Customer Support
oCommodity related strategies with Global Materials
Team member in the development and implementation of
oGlobal Supplier Rating System
oGlobal Supplier Qualification System
oCorporate Supply Based Engineering Cost Reduction initiatives. ($1.2 Million + Annually)
oGlobal SQE toolset including
Supplier Corrective Action Database (eCAR)
Internal Quality Alert System (IQA)
Supplier Claims Management System (CMT).
Led Global MRB (Material Review Board) process to align sites best practices.
Work with customers and engineering on new product introduction.
Manage the qualification process for new parts and/or suppliers.
Provide direction, training and leadership for Management and Engineers at all levels.
Solectron, West Columbia, SC
SENIOR GLOBAL SUPPLIER ENGINEER, 2003-2008
Six Sigma – Lean Team resulting in a $16-17 million cost reductions
Facilitator in the requirements definition process, by ensuring understanding Six Sigma - Lean principles.
Develop Six Sigma – Lean philosophy to support the Supplier Development Process.
Perform assessments and require corrective actions as necessary.
Design for Six Sigma (DFSS), DMAIC Six Sigma and Six Sigma Lean Black Belt training completed.
oSupplier first article inspection process, resulting in over $1M in annual cost savings.
oSupplier Localization to low-cost regions
oReducing incoming inspection at sites
oReducing the response time for Supplier Corrective Action Requests.
Global MRB (Material Review Board) process, potential annual savings of $500K per site.
New Product Introduction qualification process for new parts and/or suppliers.
Initiate Corrective Action Requests or Engineering Change Notices as appropriate.
Provide direction, training and leadership for Management and Engineers at all levels.
Solectron, West Columbia, SC
SUPPLIER QUALITY ENGINEER, 2001-2003
Implement Lean Manufacturing initiatives throughout the facility and into the supply base. The estimated finished goods inventory reduction related one of the current lean projects is a $4 Million Dollar reduction annually. Another project will eliminate over 8 million dollars of PCBA inventory by setting up a Super Market at our Solectron PCBA supplier and having daily shipments made to Columbia by pulling from the off site KANBAN.
Conduct Site Quality Systems Presentations for all potential customers. Lead and manage all current OEM customer site audits. Conduct on the average of 5 Site Quality Systems Presentations each month. Current customer base includes: Nortel Networks, Cisco Systems, Brocade Communications, NCR, NEC, Motorola, Lucent, Teradyne, Diebold, and IBM.
Create and negotiate the terms and conditions of customized Quality Plans for all new customers which are then used for the foundation for meeting each customer’s unique quality systems needs. Included in the plans are ‘Dead On Arrival’ definitions and targets, Internal Yield/Commodity Yield Targets, Control Plans, Failure Modes and Effects Analysis process, Design Reviews, Report Frequency, Supplier Corrective Action Request process, SPC requirements and long term customized quality improvement plans.
Developing automated tracking system for all defective materials in the plant. All materials and dollar amounts of inventory will be tracked using shop floor data management system. System will be used to capture incoming inspection records. Have applied same system to track all site Returned Material Authorizations. This system has allowed all defect data from critical Field Failures and Internal failures to be collected and analyzed from one system.
NEC Computer Systems., Sacramento, CA and Fife, WA
SENIOR QUALITY AND RELIABILITY MANAGER, 1994 - 2000
Developed and implemented quality and reliability performance measures
oHALT, HASS, STRIFE, DVT, and ESS.
oReduced the field Annual Failure Rate
oShortened Time to Market for Portable Products team.
Customer Quality Liaison working with Key Account Representatives and Design Teams
oDriving root cause analysis of major customer issues
oEvaluate the proposed corrective measures.
oImplemented the ‘Voice of Customer’ forum.
Promote and facilitate the use of traditional reliability analysis tools in support of new product designs.
Define requirements and implement a quality system.
Predict New Product Reliability using Probability Ratio Sequential Testing (PRST)
Manage project schedules identifying key milestones, critical path, and risk assessments and solutions.
Managed the day to day activities and priorities of engineers and technicians
Interface with Management and Engineering teams World Wide.
EDUCATION
SPC Statistical Quality Control Course based on the techniques promoted by Dr. Deming
Business Administration Focus, University of Phoenix, San Jose, CA
Business Administration Focus, Georgia Southern University, Statesboro, GA
AFFILIATIONS
Member of the IEEE and ASQC
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