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Quality Assurance Engineer

Location:
Livermore, CA
Posted:
November 19, 2024

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Resume:

Stephen T. Mahler CQM, CQA

**** ******** **** *********, **. 94551 Contacts: Cell 209-***-**** e-mail; *******@*******.***

BACKGROUND

Over 39 years of quality assurance and quality control experience in design, engineering, manufacturing, test inspection and construction with increasing levels of responsibilities. Experience in the following areas: Radar absorbent composite materials, rocket nozzle assemblies, F-35 flight hardware, rail transit facilities and systems design and construction, including heavy civil construction, manufacturing processes (in multiple industries, products, services, disciplines and facilities), testing and inspection. Implementation of Quality Assurance Requirements of the Department of Energy (DOE), Department of Defense (DOD), the Office of Civilian. Radioactive Waste Management (OCRWM) and the Nuclear Regulatory Commission (NRC), ISO 9001, ISO 17025 and Federal Transportation Administration FTA QMS Guidelines.

EXECUTIVE SUMMARY OF RELEVANT AERO JOB EXPERIENCES (14 years - in order)

F-35 Defense Logistics Agency (DLA) All Hardware – Supplier Quality Assurance Engineer (Lockheed Martin)

SBIRS Satellite Solar Array and Electronic Box Testing– Senior Quality Assurance Engineer (Lockheed Martin)

Lockheed Martin Miscellaneous – Supplier Quality Assurance Engineer (Verify)

F-16 Explosive Mechanisms – Quality Assurance Engineer (Teledyne)

Trident SLBM Third Stage Rocket Nozzle – QA Engineer (Kaiser Aerotech)

B2 Stealth Bomber Radar Absorbent Materials– QA Engineer (Hexcel)

PROFESSIONAL EXPERIENCE

Quality Management of Supplier Operations Lockheed/Martin (Indotronix) DLA ; 6/21 – 6/23

•Lead supplier quality engineering and incoming inspection Teams in assuring that contractual engineering standards are carried out and assured upon source inspection and/or receipt

•Collaborated with quality engineering, planning and manufacturing organizations to ensure quality standards are in place

•Influenced improvements to methods and procedures

•Audits of quality systems for deficiency identification and correction

•Ensured that corrective measures meet acceptable reliability standards and that documentation is compliant with requirements

•Specialized in design, incoming material, product evaluation and/or reliability

•Analyzed inspection and testing processes, mechanisms and equipment

•Supervised quality assurance tests and statistical analysis to assess the cost of and determine responsibility for products or materials that did not meet required standards

Quality Assurance Manager/Design QA Mgr (concurrently) QEI, (BART, Sac RT; 11/09 – 11/2024

Implement the Quality Management System (QMS) as the primary/co-primary contact for all programmatic Design/Construction Quality issues

Perform responsibilities outlined in Sac RT Contractual General Conditions, and BART Contractual requirements

Established, maintained and leveraged relationships with public agency tech staff, customers, suppliers and program testing/inspection companies

Write/review/edit/finalize Sac RT/BART approval of Design/Construction Quality Management Plans (DQMP/CQMP) and procedures

Issue periodical Design/Construction Quality Status Reports and/or wrote all quality ‘deliverables’ (Inspection/Test Plans, checklists, etc.)

Managed/co-managed and supported, training, performance evaluations and directed Design/Construction Quality groups

Plan, conduct and issue reports on Design/Construction subcontractors on the implementation of contractual requirements and adherence to their own design/construction quality procedures

Provided technical/engineering support for proposals, plants/materials, construction and estimating teams during pre-bid, and post construction

Performed investigations assuring positive corrective actions are implemented as a result of program NCRs and/or audit/surveillances findings

Quality Assurance Manager, AECOM, Caltrain Electrification Project; 9/2016 – 2/2021

Implemented and established a systematic approach to the oversight of both the construction contractor and the train manufacturing contractor’s quality programs.

Reviewed and approved the Quality Management Plans and procedures for design, manufacture, test, inspection, installation and commissioning activities to assure compliance with Contract requirements, the planned scope of work and FTA QMS Guidelines.

Performed audits of selected design-build contractors, subcontractors and suppliers and their implementation of their approved QA/QC procedures throughout the delivery phases; provided corrective action recommendations to JPB.

Reviewed all quality-related contractor, subcontractor and supplier submittals (DVR, DCN, NCR, CAR, FAT, etc.) for concurrence/acceptance.

Developed and submitted periodic QA reports for programmatic Caltrain funding agency and Director’s review.

Senior Quality Engineer, Lockheed Martin – Solar Array/Mechanisms/EBTL Facilities; 1/2009 – 11/2009

Provided senior-level key interface and independent verification of; quality, testing, engineering and manufacturing functions to floor-level processing in AS 9100 certified Special Programs, Solar Array, Mechanisms and Electronic Box Test facilities.

Assured proper disposition of discrepant hardware/software and assisted in the viability of cause/corrective action (FMEA) in quality and reliability measures.

Assured that quality and reliability discrepancies/trends, Q-notes and PR/MRB issues are properly addressed with Test Engineering, Manufacturing Engineering and material processing. Also participated in Failure Review Board (FRB) Fault Tree analysis & disposition.

Monitored, witnessed and assured compliance to test/inspection witness points/protocols in diverse test environments and procedures, including; thermal/vacuum, vibration, precision mechanical inspection, electrical, and software code testing/verification.

Developed and revised testing, inspection and engineering procedural directives in approved shop floor documents.

Represented LM as a Senior QA rep in verification and quality issues relating to the buy-off of DCMA/customer witness points.

Utilized Enterprise Resource Planning (ERP) and SAP Engineering systems to quickly and reliably address engineering change issues.

Assurance Manager, Lawrence Livermore National Laboratory (LLNL) – Energy & Environment Directorate & Yucca Mountain Project; 11/2001 – 6/2008

Provided independent management oversight of Directorate’s Integrated Safety Management system, ES&H and Quality Assurance (QA) organizations, activities and facilities to assure proper implementation of the ES&H, QA Programs (DOE Order 414C) and Price Anderson Amendments Act (PAAA) in a diverse set of chemistry, biology, engineering and physical science labs/facilities.

Supervised, developed, trained, directed and evaluated three direct reports assuring that facility compliance directives were properly implemented while maintaining a positive departmental image.

Managed, planned, conducted and point-of-contact for ES&H/QA Surveillances, Audits and Self-Assessments.

Managed Occurrence Reports (OR) and Issues Tracking System (ITS) deficiencies from assessments as required to properly document, track resolve conditions adverse to quality and/or safety and follow-up to Corrective and Preventive actions (CAPA).

Developed and implemented Directorate plans and procedures to assure activities are performed in a safe and secure manner and in compliance with LLNL policies & federal, state and local regulations. (OSHA, 10 CFR 830, 835, 851)

Evaluated and/or approved Quality Assurance Plans (QAP), Facility Safety Plans (FSP) and Integrated Worksheets (IWS) to assure quality, safety, health and environmental controls are properly implemented.

Served as Subject Matter Expert (SME) for all regulatory QA & Safety issues (federal, state, county, local, & air, water, waste and safety) to assure their incorporation into planning activities. (DOE Order 5480.19, Conduct of Operations)

Quality Engineer, BART - SFO, Colma, Pittsburgh, Pleasanton Extensions Program; 3/1993 – 9/2001

Participated in site inspections of complex systems components, assemblies and interfaces for assessment of equipment integrity, reliability, maintainability and operational safety. (ASTM, ANSI/ASME, AWS, IEEE & contract specific requirements)

Planned/conducted QA/QC audits & surveillances on Design Grps, Contractors, Subcontractors, Suppliers, Test Labs and NDE Agencies.

Originated, wrote & secured FTA (Fed Transportation Administration) approval for Quality Plans/Procedures for all extensions projects.

Planned and performed preliminary engineering, design, contract and spec reviews of bid packages for proper quality/test inclusions.

Reviewed/approved all Contractor /Supplier technical submittals needed to verify contractual adherence to structural, mechanical, equipment and systems integration applications. Made recommendations on Contractor’s progress payment applications.

Coordinated, scheduled and monitored all independent third-party NDE, laboratory and field testing/inspection activities.

Represented BART contract considerations on periodic Contractor reports (Inspectors Daily Reports, progress, completion, modifications/engineering changes, punch lists), and resolution of contractor/subcontractor/supplier non-conformances.

Sr. Quality Assurance Engineer, Teledyne (Pacific Scientific); 8/92 – 3/93 (F-15, F-16 ordinance/jettison mechanisms)

Prepared Inspection Plans/Procedures and Quality Manual amendments as the staff technical writer.

Performed detailed proposal and contract reviews to determine customer quality requirements and associated company cost predictions.

Participated in design, feasibility, reliability, quality and safety reviews for ordinance/jettison mechanisms

Lead team to attainment of ISO 9000 registration and participated in the on-going maintenance of the ISO 9000 system.

Prepared contract data items, including; cost/budget tracking, Quality Program plans, quality status reports, failure analysis (FMEA), internal/customer non-conformance reports.

Wrote technical test instructions/procedures to comply with destructive and non-destructive contractual requirements.

Program Quality Engineer, Kaiser Aerotech (Rockwell Collins); 7/1989 – 5/1992 (Trident D-5 SLBM)

Implemented and monitored positive pro-active corrective action plan on plant-wide Mil-Q-9858, Mil-Std-1520, Mil-Std-45662, Mil-Std-105 and Mil-I-45208 systems (GD&T; ASME Y14.5).

Reviewed Production Orders for proper integration of inspection/testing procedures in accordance with customer drawing and spec requirements.

Reviewed and approved Purchase Orders for correct quality/testing requirement inclusions and served as key point-of-contact for all incoming supplier quality inspection issues and corrective/preventive actions. (CAPA)

Initiated inspection plans (first article, receiving, tooling), lab reports and monitored machining/assembly and SPC/CPK trending.

Originated and reviewed internal and customer NCRs for accuracy, root-cause, corrective action, failure and reliability (FMECA) analysis.

Performed internal and supplier audits and monitored non-destructive examinations (NDE).

Provided liaison support with in-house customer and Navy representatives for the Trident D-5 composite/metallic rocket nozzle assembly.

Quality Assurance Engineer, Hexcel Corp. Advanced Products Division, 11/1983 – 3/1989 (B-2 Stealth Bomber)

Performed technical writing of inspection procedures and quality manual.

Provided quality liaison support as representative in supplier, customer and associated Hexcel facilities for the classified Stealth programs including close tolerance analysis of Geometric Dimensioning and Tolerancing (GD&T; ASME Y14.5).

Chaired Material Review Board (MRB).

Developed and maintained traceability documentation and control of equipment calibration, tooling and manufactured parts.

Performed process capability studies and engineering evaluations for the contouring, measuring, lay-up and installation of Radar Absorbent Material (RAM) composite structures.

Performed internal and supplier audits and initiated all QA-related supplier issues and corrective actions.

Inspection Supervisor/Machinist/3rd Shift Supervisor, Proto Stamping Inc.; 1/1981 – 11/1983

Education: Saint Mary’s College, Moraga, Ca.; BA Degree, Management

De Anza College, Cupertino, Ca.; AS Degree, Quality Assurance

Certifications: ASQ; (American Society for Quality) - Certified Quality Manager (Cert. #3632)

ASQ; (American Society for Quality) - Certified Quality Auditor (Cert. #12042)

BART Engineering Certification; Engineering Safety

Training: Geometric Dimensioning & Tolerancing (GD&T – ASME Y14.5M, Revision 1994)

IBM -Catia, Computer Aided Design (CAD); 3D, Curves and Surfaces, NC Mill

Affiliations: Senior Member - American Society for Quality (ASQ), since 1986

Awards: LLNL (Energy and Environment Directorate) – Certificate of Accomplishment; efforts, dedication and service as the lead technical representative for the metal specimen corrosion testing project.

Misc.: Department of Energy (DOE) LLNL ‘Q’ ‘Secret’ security clearance (2008; inactive)

Department of Defense (DOD) Hexcel ‘Secret’ security clearance (1989; inactive)



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