Quality Engineer Process

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John T. Brewer "Tim"

*** ***** ***** ****

Lewisburg, Tennessee 37091

Phone: 931-***-****

JOB OBJECTIVE: Management/Quality Engineering

WORK EXPERIENCE:

July. 2022 to Present: Marelli North America (formerly CalsonicKansei/Kantus Corporation), 201 Garrett Parkway, Lewisburg, Tennessee 37091 July 2022 to Present: Senior Quality Engineer, Electronics Division Responsible for quality support for Plastics Division Business Unit for products delivered to Mazda, Lordstown Motors, Honda, Nissan (Customers in Europe, Brazil, Mexico, and the US). Perform both Supplier and Customer Quality support. Submit PPAP, PSW, FSCR, and other required documentation for new product launch and part change requirements. Problem solve customer and supplier issues and help to implement required corrective actions. Lead CFT activities to reduce inventory, improve scrap, reduce warranty cost, improve operation efficiency, and improve internal and customer quality for responsible Plastics plant departments. Worked to move and manage suppliers from China to more profitable regions for Marelli. Jan. 2009 to Present: Marelli North America (formerly CalsonicKansei/Kantus Corporation), 201 Garrett Parkway, Lewisburg, Tennessee 37091 Jan. 2009 to July2022: Senior Quality Engineer, Electronics Division Responsible for quality support for electronic products delivered to Tesla, Visteon and Nissan

(Customers in Europe, Brazil, Mexico, and the US). Product responsibilities are for radio/CD switch assemblies, heating and cooling control switch assemblies, Lithium Battery Controllers and Inverter

(Leaf) and BCM product lines. Perform both Supplier and Customer Quality support. Submit PPAP, PSW, FSCR, and other required documentation for new product launch and part change requirements. Problem solve customer issues and help to implement required countermeasures. Lead CFT activities to reduce inventory, improve scrap, reduce warranty cost, improve operation efficiency, and improve internal and customer quality for responsible product lines. Have lead Quality Circles activities and have won 3 of past 5 North America competitions. Improved Electronics from a chronic poor supplier to Nissan to achieve 7+ years of zero defects. Oct 2005 to Dec. 2008: Marelli North America (formerly CalsonicKansei/Kantus Corporation), 1 Calsonic Way, Shelbyville, Tennessee 37061 Oct 2005 to Dec. 2008: Corporate Quality Strategic Planning and Warranty Manager: Coordinate activities which ensure compliance to TS 16949 requirements at all US operations. Develop fiscal year quality plans for all US and Mexico operations. Responsible for improving warranty cost and claims data at all US and Mexico operations. Determined internal improvement projects focus areas, supplier development and improvement activities, and warranty improvement and supplier chargeback activities. Evaluated quality systems needed for improvement and work to maintain standardized systems at all locations. Communicate Quality Performance results to CK- Japan Corporate Quality. Monitor Key Performance Indicators at all US and Mexico operations. Recovered $4 million in warranty cost and improved 3 MIS claims by 30% in first 8 months of new improvements activity. Special Training in Time Management 2

May 2008 to June 2008: Interim Quality Manager – Lewisburg Plastics Responsible for quality assurance activities at the Plastics, Assembly, and HVAC operation’s

(Managed 33 quality positions in the facility). Managed quality responsibilities for 2009 Maxima product launch. Developed strategy to respond quickly and effectively (Cross Functionally) to new model quality concerns.

Oct 2005 to Sept 2007: Corporate Quality - Planning Manager Responsible for evaluating and standardizing the Quality Systems used by all manufacturing locations within CalsonicKansei’s North America operations. Recommend and Coordinate Quality improvement projects necessary to satisfy the customer’s expectations/specifications. Planned fiscal year activities for Corporate Quality Department. Report all locations overall Quality Performance

(Key Performance Indicators) to Executives and CK-Japan Corp. Quality. Dec. 1998 to Sept 2005: Marelli North America (formerly CalsonicKansei/Kantus Corporation), 201 Garrett Parkway, Lewisburg, Tennessee 37091 April 2005 to Sept. 2005: Altima IP and ESP Manager Managed the activities of 90 plus personnel in the Nissan Altima Instrument Panel and Electrostatic Paint manufacturing departments. Performed Value Stream Mapping (Lean Mfg.) activities to reduce WIP, improve efficiency, better utilize floor space, and reduce labor (6 techs reassigned). Reduced scrap by 40%, reduced manpower by 23%, reduced WIP by 45%, improved efficiency by 20%, and reduced floor space requirements by over 70%. Responsible for Safety and housekeeping improvements within the area.

April 2003 to March 2005: 5ZQA Support Engineer (Quality Engineer) Support Quality Systems Improvements within all departments at CKNA-Lewisburg and CKNA- Manchester (Electronics). Trained on new QSES (Japanese Quality Evaluation System) system and have performed audits internally and at other CKNA sites. Prepare cost savings reports for improved quality systems. Trained on TS 16949 and have performed several internal audits. Train Engineers, Quality Personnel, Department Managers, and other support personnel and also at other sites (Canton and Vicksburg Miss) on how to use and apply 5ZQA system. See comments below, in April 2002 section.

September 2002 to February 2003: SIA Quality Improvements Engineer (Project Special Improvements)

Responsible for improving Subaru Isuzu’s Product Quality Systems within Kantus. Implemented new assurance systems and improved existing Quality Assurance Systems; Work Instruction, Inspection Instruction, First Article Check, Process Improvements, Floor Audits, and most importantly “Training” of hourly and support personnel. Improved Quality Rating from 58% to 94%.

April 2002 to August 2002: 5ZQA Support Engineer (Quality Engineer) Introduced a “New” Continuous Quality Improvements Program (5ZQA) to all Manufacturing Departments, as well as the Engineering and Quality Assurance Departments This system measures current quality assurance levels within a product line and determine areas for improvements. The Assurance Level has to achieve a certain level before a product line is approved for a special ranking. Important factors are reducing Customer and In-house PPM levels to a targeted level, while ensuring systems are in place to prevent customers from receiving defects. Within this system, Kaizen activities are also implemented. One of the main benefits of the 5ZQA program is to bring various departments together to focus on potential issues and resolve them before they occur. If problems have occurred at the Customer, systems are set in place to keep same defect from 3

reoccurring. Responsible for identifying the need for and then implementing defect detection systems and process improvements. Perform QS9000 internal audits. December 2000 to February 2002: Manufacturing Engineer (Injection Area) Responsible for SIA, Honda, and AutoLiv Air Bag Manufacturing within the Injection Department. Responsible for reducing scrap and improving efficiency within these areas. Responsible for launching new Maxima XX program (56 new tools), evaluated and approved new injection area molds, purchased assembly equipment with Poka Yoke systems. December 1998 to November 2000: Plastic Injection Process Engineer Responsible for troubleshooting and improving all departmental processes (molding and assembly). Accountable in developing machine and robot processing parameters for new and existing tooling. Ensure that all QS9000 documentation was adequate, accurate, and current. Reduced die changeover time to single minutes on several machines. Improved knowledge of existing setup personnel and have trained new injection department setup personnel. Initiated new Standard Operating Procedures (SOS) for all processes within department Worked with "Tiger" team to reduce cycle times, scrap, and regrind.

Special training in Robotics (Star), Valve gating, Sonic and Vibration Welding, and Gas Assist Molding

May 1991 to Dec. 1998: Wiper Systems Division, ACD Tridon Inc. 101 Motivation Drive, Lawrenceburg, Tennessee 38464

January 1998 to Dec. 1998: Injection Molding & Assembly Area Performance Team Leader Responsible for managing area department budgets. Reported on why monthly targets were met or not met. Ensured that departmental cost reduction efforts were introduced on time and below budget. Responded to and resolved customer quality alert issues. Performed Kaizen activities. Responsible for developing, implementing and qualifying new downline equipment for the SLP and BB Assembly Departments (reduced number of machines from 3 to 1 in 17 different workstations

(eliminated 34 machines total), reduced floor space requirements by 75%, reduced WIP inventory between operations from 350 parts to 75 or less.

August 1995 to January 1998: Injection Molding and Assembly Area Process Engineer Responsible for implementing profit improvement projects, target goal of $650,000 annualized savings was achieved for fiscal ‘97-98 (regrind/material reconciliation, cycle time reductions and process improvements to achieve favorable operating variance). Evaluated and made recommendation on die-etching process to improve part appearance. Responsible for origination and implementation of QS9000 operating procedures for the assembly and molding area, updating, and operator training (ACD Tridon became QS9000 Certified Feb. ‘97). Lead “Kaizen” teams in problem solving and process improvement activities. Perform DOE’s on injection molding machines to determine optimum processing conditions. Responsible for placing POKA–YOKE devices on blade and refill assembly equipment. Developed equipment specifications for new assembly downline and injection molding equipment. Work with CFT to develop and implement new wiper systems products.

Special training in Moisture and Viscosity testing of plastic materials. April 1993 to August 1995: New Products and Process Engineer Responsible for implementing new product lines (Flasher housings and Canadian Gun parts) to Wiper Systems Division. Purchased and troubleshooted molding, downline, and auxiliary equipment. Performed molded part capability tests. Wrote FMEA’s and control plans for the new product line. Established Engineering Specifications for all new plastic materials. 4

Special training in BASF Plastic Material and Design, and Microsoft Software (Excel, Word, Schedule+, etc.

May 1991 to April 1993: Process Engineer/Industrial Engineer Responsible for initial plant start-up (Tridon moved from Canada in 1991) supervised and trained operators in all manufacturing departments. Supervised and trained the Injection Molding setup operators on various molding equipment (Nissei, Engle, Van Dorn), developed setup procedures and instructions. Evaluated tooling for modifications to enhance part quality, established machine preventive maintenance schedules, and updated and generated FMEA/Control plans and Inspection Standards. Established PM scheduled for various equipment. Analyzed, purchased, and proceduralized regrind materials for use in the aftermarket blade production which saved $325,000 annually.

Special training in 8-D problem solving techniques, GE Share the Knowledge (Plastics Design and Processing Seminar), Quattro Pro, Word Perfect, and allClear. Sept. 1981 to May 1991: Automotive Division, Modine Manufacturing Company 2009 Remke Avenue, Lawrenceburg, Tennessee 38464

April 1987 to May 1991: Process Specialist/Industrial Engineer Responsible for developing cellular manufacturing approach, implementation of JIT system

(Reduced WIP from 120 plus units between operations to one unit in the welding and testing area), justify and develop backup data for capital expenditures, prepare detailed analysis of manufacturing costs and projected cost reductions. Responsible for the development and organization of two major plant expansions.

Special training in Cadkey and Lotus 1-2-3

October 1984: Standards Analyst

Responsible for plant layout revisions, line balancing, budget evaluations, setup time reductions, and job description and factor evaluations.

Special training in S.P.C., Group Interact sessions November 1983: Standards Technician II

Responsible for machine and manpower studies, value analysis, and establishment of Bill of Materials. Special training in Multiplan Spreadsheet and Supervision. October 1982: Standards Technician I

Responsible for developing best methods, work procedures, and labor cost through use of PDT analysis and stopwatch studies. Special Training in Pre-Determined Times Methods. EDUCATION:

B.S. Degree in Business, Middle Tennessee State University, Agri-Bus, with minor in Management and Marketing

Lawrence County High School, Lawrenceburg, Tennessee PERSONAL:

Family: two children; Lindsey age 37 and Will age 36 Outside Activities: coached Babe Ruth Baseball for 22 years, boating and most outdoor activities REFERENCES:

To be provided upon request

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