Quality Professional

John D. Nelson

Email: ***********@*****.***

*** **** **** **** (C) Phone: 409-***-****

Conroe, Texas 77303

Professional

Degreed, process-oriented engineer with over nineteen years of proven success in the Oil & Gas, Automotive, Aerospace and Commercial Products Industries who accomplished multiple aggressive company objectives. Expertise in Supplier development/management, Cost Analysis & Estimation, Operations, Manufacturing / Quality Management, Cost of Quality savings, Industrial Engineering, and Safety Management.

2019 -- Present Sabbatical

Life throws many curves, and sometimes one must choose to take care of family first. My elderly mother has experienced a number of medical and home care difficulties since my father passed in 2019. Due to her health, and health care issues, I spent a considerable amount of time traveling from my home in Texas to her home in Tennessee in order to ensure she was adequately cared for, to help coordinate other issues, and to spend time with her. Obviously, this has taken quite a bit of time and effort, and continues to this day although to a lesser degree. Add to this, my wife was involved in a severe car accident in the fall of 2020, which resulted in her experiencing multiple, incapacitating injuries. My wife required extensive care for quite some time as she recovered. I became her nurse and driver during that time due to those incapacitations. As if that wasn't enough, my wife contracted bilateral bacterial pneumonia in the fall of 2021. She was hospitalized for several weeks, and then required a lengthy at home recovery. Again, I was her nurse and driver. Now the family life is settled, and everyone is recovered and in a good place, it is time for me to focus on continuing my career.

2015 -- 2019 Quality Specialist, Red Claw LLC Houston TX (Oil & Gas)

Responsible to lead team and be the management representative, in implementing ISO 9001:2008 to successful certification & maintenance for the rebuild, manufacture of ac/dc generators, drilling motors, bug fans and blowers for oil & gas rigs both land and sea, which included success in:

•Selection of registrar (WCS), audit training (BREWER & ASSOCIATES) and completion of Internal Audit Training and other training programs

•Implementation of ISO 9001:2008 plant wide in 4 months to successful certification audit

•Initial certification resulted in 0 findings, 0 minors, 0 majors during complete registration audit, by using the KISS principle, leaving many continuous improvement opportunities for later.

•Managing over 40 corrective actions to close, using 8D methodology

•Business case review resulting in decision, not to perform in-house calibration as it was cost prohibitive

•Identifying variance during calibration of hand held devices resulting in modification of NASA certified procedure to improve calibration of inside micrometers that reduced .0005” variation in device

•Implementing in house validation procedure of questionable measurements, using Gage blocks

•Developing functional testing parameters and procedure for in-house NDT, magnetic particle testing

•Identifying a variance in the FARO CMM programming, resulting in ECN driven spec. change, leading to the removing of 2 plane parallelism measurement from print, as the FARO CMM algorithm at .002” capability, wasn’t accurate enough to match a 1 plane of geometry via hand held measurement device

•Managing calibration system of over 700 hand held and machine mounted devices controlled by Visual Quality Enterprise for automated calibration scheduling.

•Implementing weld testing protocols for employees, to meet customer requirements to AWS D1.1

•Leading team in successful certification to IECEx 80079-34 Explosives Atmospheres

•Leading team in successful recertification to ISO 9001:2015 standard

•Managing Supplier Approval list and used Survey Monkey as feedback tool for suppliers and customers

Added Safety Management to current position responsibilities in Feb 2016

•Leading team in development, review of safety program manual, safety training and daily safety issues

•Maintaining and performing employee orientation for general safety, position specific safety, and coordinated and performed in CPR, Fork-Lift, fire safety training, or on any relative subject as needed

2013 -- 2014 On Sabbatical, Moved to Texas

2011 – 2012 Cost Optimization Engineer ACORD HOLDINGS Rochester Hills, MI (Automotive)

Responsible for program costing of all new research, future programs and changes to existing programs.

•Programs covered were automotive interior IP, Door, Pillars, Consoles, Doors class A surface plastics, components and assemblies as a Tier Two supplier to OEM’s.

•Responsible for conversion of manual estimating system to function in the new Dynamix AX SAP system.

•Support all functions in costing, pricing negotiations with customer or supplier, including program financial analysis quoted versus actual, and various business case analysis decisions tasks.

2010 – 2011 Sr. Cost Optimization Engineer METHODE ELECTRONICS Southfield, MI (Automotive)

Responsible for program costing of all new research, future programs and change s to existing programs, conversion of manual estimating system to function in the new Dynamix AX SAP system. Support all functions in costing, pricing negotiations with customer or supplier management, including program financial analysis quoted versus actual, and various business case analysis decision. Included Industrial engineering role as tasked.

•Assisted plant layout, work cell design initial product costing for paint lines, laser etching, pad printing up to assembly for the 250k sq ft facility layout of the vertical integration plan, for a program building 1.3 million assemblies a year, up to board approval of project and machine purchases as of July 2011. The finished assembly comprised approximately 56 million plastic & 93 million electronic components.

•Active program reductions for FY2012 at $1 million with potential booking of improvements in program profitability on FY2013 program exceeding $3 million annually, dependent on vertical integration plan, leveraged and negotiated pricing, material replacement and design improvements.

•Worked with Purchasing group in establishing improved procedures and methods to achieve targeted 18 inventory turns, vs. an avg. of 9 turns, potential reduction in inventory costs of minimum $3.5 million

•Establish reporting functions and matrixes for cost reduction methodology and procedures for programs, coordinated with other facilities.

2001 – 2009 Sr. Cost Estimator (2006 – 2009) ACH LLC Dearborn MI, Cost Estimator (2001 – 2006) VISTEON CORPORATION, Van Buren TWP. MI (Automotive)

Promoted to Sr. Cost Estimator 2006, responsible for liaison between Engineering, Finance, Purchasing, Sales and support of program management for analysis of material and process changes in development of target pricing in Gate Reviews as requested.

•Led activities for 1,920 minor/major changes and 117 additional assignments over 8 years.

•Participated in over 40 different VA/VE cost reduction activities and Supplier negotiation

•Helped to establish new product assumptions, costing, and supplier integration within 45 day compressed timing for a program recovery plan, after the customer rejected the original design during Gate 2 review

•Provided costing and process expertise support for the Lincoln Blackwood project during Gate 3 Review, protecting Program Management from being leveraged into an improper implementation and associated cost structure, of a process the customers own engineering group hadn’t approved at that time

Cost Estimator responsibility for management of supplier base, and customer performance of parts component quotations, costs, and estimation of tooling, material and manufacturing costs for engineering changes.

•Developed Excel based module estimating tools as well as used commercial estimating programs

•Zero based & value added costing methodology

•Majority of changes estimated off engineering generated assumptions (ECN’s), and print driven assumptions when available!

oInjection/Compression/Insert molding

oLight Stamping, Casting/welding. Light Machining

oWire Harness

oPlating / Painting – metals / plastics

oLTCC Ceramics

•Implemented individual save initiatives which averaged of $1.34 million in savings 2004-2005

•Establish standardized bank build procedure and successfully introduced this change to supplier base

oDifferentiated between Unionized and non-unionized as each carried a different labor load

oResulted in over $5 mil in real savings in first year for my commodity responsibility alone.

•Trained Purchasing / Buyers on product knowledge and processes to recognize opportunities or supplier omissions

1999 –2001 Operations Manager (2001) Quality Manager (1999-2001), QUALITY INDUSTRIAL SERVICES (QIS), INC. Romulus, MI (Automotive)

Promoted to Operations Manager 1/2001, managed a 120-person 3RD Party containment facility, exercising P& L activities successfully implementing cost reductions while maintaining Quality Manager responsibilities.

•Reduced administrative costs by $25,000 per month by restructuring cell phone usage and contract, re-evaluating rental contracts for delivery vehicles, scanner/printer units, forklifts and on-site security.

•Developed & implemented portion of Administrative handbook that modified hourly hiring process, reducing insurance & benefits costs for hourly employees over the first 90 days of their employment.

Quality Manager duties were to lead the maintenance & implementation of the quality system and be the management representative, at both the home office and other company facilities.

•Led the -72% reduction in procedural non-conformances in 3 months, and -81% decrease in traceability non-conformances within first year through the implementation of standardized training for hiring, training, & evaluation methodology for hourly personnel and management.

•Without prompting, I teamed with the IT dept. to review, re-design & modify structure of current Operations Database which allowed commonization in 18 locations of the P&L functions for contracts, reporting, invoicing, & quality data while making program SQL capable which resulted in:

oProduction data entry errors decreased by -80% in 5 weeks time after launch (Romulus Office)

o$450k average savings per year labor costs identified as the new reporting function automatically compared billed versus hours paid in the QIS payroll system.

oIdentified lost billing of customer contracts opportunity for AR by approximately $1.2 million between 1999 to 2001 resulting in modification of AR practices to correct.

oLong term development allowed reduction of data entry personnel from six to one

•Salvaged ISO9002 quality system from de-certification, eliminated 26 nonconformities from system audit to maintain ISO9002 certification for two facilities.

•Implemented training of all union representatives on proper procedure for filing grievances, to eliminate a perceived issue. Grievances were reduced from 20+ per month to 2 avg. per month.

•Customer supplied calibrated tools for inspection process

•Achieved successful re-certification of facility to ISO9002 with only ten minors for complete audit.

•Successfully managed over 70 corrective actions to close using 8D methodology

•Consulted Battle Creek facility on development and successful implementation of TS16949.

•Team member in development of standard contractual template/procedure for containment, technical representation, and light assembly that led to eventual first light assembly contract, with Goodyear Inc.

1998 – 1999 Quality Manager ASTECHNOLOGIES, INC. Monroe, MI Laminated Products (Automotive)

Quality Manager, with responsibility for implementation of a QS9000 quality systems and Management Representative while managing day to day plant quality and functions of 14 technicians.

•Multiple DFMEA & PFMEA analysis activities for PPAP submissions

•Successfully managed over 30 corrective actions to close using 8D methodology

•Performed DOE on Adhesion strength tests

oRetraining of company techs, and coordination with customer QA, to the updated test method/procedure, enabled a -52% reduction on internal non-conformances, and -71% reduction in external non-conformances by end of the first year

•Implementation of MRN (Material Return Notice) system in first three months

•Performed DOE on dimensional quality issues resulted in correction of incoming material GDT standards for laminated product via ECN, reducing dimensional failure errors by -62% in first three months

•Performed DOE on Visor product eliminating the “Squareness” specification failure issue

oSix Sigma verification of cutting process supporting 8D corrective action solution on visor product, and incoming material spec. change via ECN, eliminating $250,000 in expedite charges and charge back penalties

•Performed DOE on sheet slicing operation leading to 2nd unit purchase to alleviate capacity issue

1995 – 1998 QS9000 Coordinator (1997-1998) CPX, Inc N Vernon, IN Quality Manager S&S Plastics, Kentland IN (1995-1997) (Commercial, Automotive)

Promoted to QS9000 Coordinator & Management Representative for CPX Inc from Quality Manager role at S&S Plastics (1998) to develop and implement QS9000 company wide with duties as Industrial Engineer

•Eliminated processing issue on insert molding operation (misplaced fans blowing air on press barrel from operator positioning, resulting in short shots) addressing multiple MRN’s & non-conformances

•Multiple DFMEA & PFMEA analysis activities for PPAP submissions

•Refined blower & water valve manufacturing assembly into a C cell layout, JIT material flow, labor requirements including rotating break system for 4 production lines, moving lines from 10,000 sq ft to just over 5,600 sq ft.

oAdded 1 work station and modified 1 work station to balance line timing for blower motor assembly and over 4 weeks, increased the productivity of the blower assembly process by 265% (164 per shift to over 600 per shift) using my “Tim Hortons” method of motivational challenge.

oAdded 1 work station and fixturing to force a 1 piece flow in the water valve assembly process, increasing productivity by 30% in a four-week period eliminating On-Time delivery & OT issue.

•Developed QS9000 system, implemented up to, and including pre-audit for QS9000 qualification.

Quality Manager, was responsible for developing a quality systems in plastic injection/insert molding facility while managing day to day plant quality engineering and management functions

•Implemented SPC controls, including the training of my 4 technicians and internal auditors.

•Reduced amount of returns by -75% (dryer controls on glass filled nylon) and fitment concerns calls for dimensional issue in battery charger case product by -45% after the first year.

•Led the development, implementation, maintenance and training for:

oLot & product traceability system w organized FI/FO resin storage

oStandardized documented process control system

oFirst piece layout of insert injection molded product and samples retain program (part & raw resin). Implementation of this, allowed me to test a replicated ASTM impact test, to disprove a customer warranty chargeback for a gross Cost of Quality savings of $2.14 mil

oSuccessfully managed and closed over 20 corrective actions using 8D process

oTrained on Six Sigma process at Motorola University

1992- 1995 Supervisor LTCC. CTS Microelectronics, W.Lafayette, IN (Aerospace, Commercial)

Led twenty-seven technicians in the (class 10,000 clean room) manufacture of LTCC (Low Temperature Co-fire Ceramic) MCM (Miniaturized Communications Modules), Thick film manufacture.

•Managed inventory and traceability using AS400 based MRP system under MIL STD 1778 requirements along with CMM programming for production screen tool certification to reduce scrap

Other Skills: Automotive painting, plating & metallization, ERP / MRP systems, Calibration system control, Minitab, Visual Quality Enterprise, Auto-cad, Solid-works, Visio, CQE & Six Sigma (Motorola U), Cost of Quality, Automotive style SAP (Suite Application Protocol), Shainin SPC philosophy, Fishbone Diagrams, 5Y, 5S, JIT, Kaizen, NDT, PC Board mfg., Light stamping & Interiors, (Molding) Plastic Injection, Insert, Foam in place, MBA executive training

Educational Background B.S. in Industrial Technology 1991- Purdue University, West Lafayette, IN

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