Quality Engineer

Farryl Atherton

*** ******** **.; Huntsville, AL 35806 Cell 563-***-**** email: ***********@*****.***

Experience at - Internal Audits, Layered Process Audits, Supplier Quality Audits and Supplier RC/CA, Work with diverse teams of specialists to imple, maintain and enforce quality system, measure, analyze and improve performance, Problem Resolution, 8D Root Cause and Corrective Action Analysis, Customer Warranty Investigation, Time Study, Technical Writing / Documentation, - Teaching, Training the use of SPC Methods, Minitab, Microsoft Office, Word, Excel, PowerPoint, Visio, - Special Projects Management. Experience performing parts layouts and operations layouts, - Technical Consulting.

Proficient at investigating product and process issues to focus on prevention by identifying process activities and solutions to minimize quality issues. Implemented Quality Management System (QMS), ISO 9001, QS9000

PROFESSIONAL EXPERIENCE

Mindlance - Union, NJ; 256-***-****, June 2024 to Present

Contract Inspector II for Blue Origin, (Huntsville, AL)

-Aerospace rocket engine manufacturer

Inspect critical flight hardware for various spaceflight systems.

Perform detailed inspection of Engine structural, electrical, and mechanical assemblies and systems using CAD models and Blueprints

Perform damage characterizations

Verify Assemblies for conformance against engineering requirements

Document nonconformance's in accordance with internal procedures.

Aerojet Rocketdyne, Inc. (L3Harris) - Huntsville, AL; 256-***-****, Oct 2021 to Apr 2024

Sr. Quality Engineer Defense & Aerospace rocket engine manufacturer

Experience in solid rocket engine components or rocket production environment

MRB member, work with RC/CA items quarantined in Material Review Cage.

First Article Inspection Plan and Report development .

Address internal quality issues on products to reduce defect rate with problem solving Analysis (RC/CA)

Control of Nonconforming Hardware, high degree of understanding

Stock checks, Stock sweep

PRO Unlimited; San Francisco, CA; 800-***-**** May 2021 to Oct 2021

Contract Sr. Quality Engineer for Aerojet Rocketdyne, Inc., (E. Camden, AR), orig 6 wk ext to 6 month.

-Defense & Aerospace rocket engine manufacturer.

First Article Inspection Plan and Report development .

Validating work instructions to the contract requirements, Technical Data Package and drawing.

Mindlance; Union, NJ; 877-***-**** Mar 2020 to Apr 2021

Contract Quality Engineer for Johnson Controls Inc., (Marinette, WI), orig 6 wk ext to 1 yr.

-Fire protection equipment manufacturer.

Institute corporate Audit System for departments

Maintain records and analysis tracking of eLPA’s, Corrective Action’s, Deviations, Internal Audits and L2 and L3 submission presentations for L2/L3 levels of JCMS (Internal form of ISO System).

Aditi Consulting; Bellevue, WA; 425-***-**** July 2019 to Mar 2020

Contract Quality Engineer for Caterpillar Inc., Hodges Casting Products, (Hodges, SC), orig 3 month ext to 9 month.

-A startup Caterpillar Iron foundry casting products for use on Caterpillar equipment.

Creating product and process quality tracking systems.

Prepare documentation for PPAP’s with chemical and physical test result.

RGBSI - Rapid Global Business Solutions, Inc.; Troy, MI; 248-***-**** June 2019 to June 2019

Contract Quality Engineer for GKN ePOWERTRAIN (Newton, NC), rush assignment request per needs of customer.

-Automotive components for transmissions by MIBA Steeltec. s.r.o.; Vrable, Slovakia. EU.

Perform full Systems Audit, Control Plan Walk thru for two part numbers and Capacity Run @ Rate review following GKN system of documentation. This is an IATF 16949 environment.

Johnson Service Group – Oklahoma City, OK; 770-***-**** Oct 2018 to Mar 2019

Contract Quality Engineer for Ducommun Inc., Tulsa, OK, orig 6 wk ext to 6 month.

-Aerospace & Defense custom Circuit Board Mfg.,

Review several hundred Bill of Materials and mfg. specifications to verify correct material coating on electronic parts used on national defense systems circuit boards fabrication. This is an ISO 9001 / AS9100 environment.

Reliance One – Auburn Hills, MI; 248-***-**** Mar 2018 to July 2018

Contract Quality Engineer for Cooper Standard, Surgoinsville, TN, orig 3 month ext to 4 month

-Automotive components for fuel systems, brake systems and transmission oil cooling,

Submitted 30 APQP PPAP packages for parts manufactured on new assembly machine to various customers.

Perform Run at Rate validation studies with summary reports on new assembly machine as various parts are cycled.

Team Quality Services – Auburn, IN; 866-***-**** Mar 2017 to Feb 2018

Contract Quality Engineer (3 different assignments)

1- Automotive brake systems fabrication, Akebono Brakes, Elizabethtown, KY Mar 2017 to May 2017

Quality systems Engineer, Ensure manufacturing process matches documents in preparation for ISO audit.

2- Bosch Home appliance installation component packages, DataPac, Richfield, NC Aug 2017 to Oct 2017

Supplier Development Quality Engineer: Establish Quality standards, Establish Quality tracking system, Lead 3rd party sorting operation, Drive process improvement using data driven problem solving.

3- Components for TI Fuel Systems, Ligonier IN and Hitachi Automotive, Harrodsburg, KY ; Nov 2017 to Feb 2018

Supplier Quality liaison; Resolve backlog of warranty issues of microscopic defects.

Confirm quality issues, and provide written, measured, photographed, illustrated feedback as Resident Quality Engineer over 3rd party sorting at customer location.

CalsonicKansei - Shelbyville, TN; 931-***-**** Nov 2013 to Mar 2017

Quality Engineer

Manufacturer of Automotive components and fabrication of HVAC units, radiator fabrication and injection molded heat exchange condensers, transmission oil cooler, Fan blades, automotive vehicle front end supports.

Develop, write, implement, and maintain quality assurance methods, Poka-Yoke error proofing, statistical techniques with Minitab, document alignment, MSA GR&R studies, review GD&T characteristics and results.

Ensure the product meets or exceeds expectations to reduced waste, TS16949 / IATF 16949 audit involvement.

Compile and submit production APQP PPAP (Warrant, Process Flow, PFMEA, Control Plan, Measurements, MSA, GR&R, write Test Lab reports, supplier data) to customers for approval. Write shop instructions and procedures.

Supplier development corrective action (SCAR) review with PPAP submission, supplier scorecard.

International travel for supplier quality audits and tooling validation, for tooling qualification.

Address internal quality issues on products to reduce defect rate with problem solving Analysis (CAPA) and Kaisen Continuous Improvement, Customer Warranty investigation, data analysis for HVAC units and Radiators.

HRU Technical Resources - Rock Island, IL; Oct 2011 to Feb 2013

(Contract) Production Process Surveillance Auditor for US Army, at the Rock Island Arsenal.

Facility ability for foundry, forging, machining, heat treating, plating and assembly.

Conduct surveillance audits of manufacturing operations in production cost centers including stamping, forgings, laser cutting, hi-pressure water cutting, welding, machining and many other processes.

Ensure the process integrity is being performed by the operator compliance with the process documents.

Conduct various special departmental reviews as requested by management writing comprehensive reports.

Produce AIAG Process Flowchart, FMEA & Process Control Plan for foundry and plating dept.

Geometric Americas - Moline, IL Apr 2010 to Oct 2011

(Contract) Consulting Industrial Engineer for John Deere (4 assignments) fabricating Motor Graders, 4x4 Farm Tractor Assembly line, Drive Train Assembly, Drive Train Machining.

Established routings, methods, safety and ergonomic improvement, labor standards of moderate scope.

Determined data of man / movement, equipment, materials and sub-parts used for work knowledge at each assembly work station writing all instructions.

Perform Time Studies for drive train machining facility machining centers.

Installed process tracking stations. Coordinate with support personnel & facilities contractors.

Romeo RIM Inc. - DeWitt, IA Apr 2003 to Dec 2008

Quality Manager / Production Supervisor / ISO Coordinator

A tier 1 supplier to John Deere, Case New Holland, CAT, and others. Reaction Injection Molded rigid urethane body panels, fenders and hood covers, utilize robot trimming and either in-mold or post mold catalyst paint.

Write Quality Manual and all documents for organization to implement and achieve ISO 9001 registration and audit for compliance.

Follow Automotive Class-A paint standards for production paint applications for Color and Gloss.

Perform Internal Audits, develop Process Flow Diagrams, (PCP) Quality Control Plans, and FMEA’s, develop 8D Corrective Action Preventive Action (CAPA) and CpK Capability Studies to provide APQP PPAP’s and ISIR.

Warranty Claims, Investigates, gathers and analyze data and implement solutions.

Communication skills to work closely with customers to Establish Quality Standards, supplier interactions.

Lead and participate in New Product Introductions, Cost Savings and Containment.

Supervisor assign work, scheduled operators for Molding, Finishing and Assembly of Product.

Schneider National Corp. - Green Bay, WI July 2002 to Apr 2003

Over the Road Semi Truck Driver

Nation wide freight transportation.

Perform daily Preventive Maintenance safety check on truck and trailer.

Pick up and deliver freight from coast to coast and border to border.

Metform LLC Corp. - Savanna, IL Oct 2001 to Apr 2002

Quality System Supervisor

Manufacturing Hot forged steel products to semi-truck builders.

Maintain and update ISO/QS-9000 writing documentation, writing work instructions, develop forms and process flowcharts.

Perform Internal quality / ISO / process audits, write reports and coordinated with the 3rd party auditor.

Centro Inc. - North Liberty, IA Mar 1999 to Sep 2001

Quality Engineer

Manufacturer of Rotational molded plastic products. A tier 1 supplier to John Deere, CAT and others.

Facilitate quality improvements and resolve component GD&T and specification issues.

Create Process Flow Diagrams, write documents, write Quality Control Plans, write FMEA’s, develop Corrective Action Preventive Action (CAPA) and provide PPAP’s and ISIR, establish GR&R Studies.

Argo Manufacturing Corp. - Thomson, IL Sep 1990 to Feb 1999

Quality Manager

An OEM tier 1 supplier of Compression and Injection Molded rubber & silicone parts to big 3 automotive manufactures.

Established quality standards for parts produced by compression and injection rubber molding.

Achieved Ford Q1 Preferred Supplier rating, Certified Supplier to Delphi Automotive and many others.

Write Quality Manual and all documents, work instructions and procedures needed to implement and achieve ISO 9002 / QS 9000 certification program.

Perform supplier quality audits of steel stamping suppliers, review supplier corrective actions, and write reports.

Teach SPC methods to reduce the scrap rate which improved efficiency and lead (MRB) defect management.

United Technologies-Engineered Systems Div. - Niles, MI Sep 1987 to Sep 1990

Quality Engineer and Special Projects Manufacturing Supervisor

An OEM tier 1 supplier of Steering wheel & air bag covers. A tier 1 supplier for automotive customers.

Wrote product Process Control Plans, FMEA’s and procedures, performed Supplier Quality Audits and reports.

Write and provide PPAP’s and ISIR, as required for APQP, establish GR&R studies.

Establish Automotive Class-A paint standards for production paint applications for Color, Gloss and Grain.

Use Quality Tools to perform Internal Audits, create (PFD) Process Flow Diagrams, write (CP) Quality Control Plans, write (FMEA’s), develop 8D Corrective Action Preventive Action (CAPA), provide PPAP’s and ISIR for APQP, establish GR&R Studies. Writing procedures and work instructions.

As Manufacturing Supervisor trained several new manufacturing and assembly crews to have the highest shift output and the least defects aimed at zero defects setting a new company standard.

Thermoplastics Inc. - Mishawaka, Indiana Feb 1983 to Sep 1987

Asst. QC Mgr., SPC Coordinator, Materials Lab Mgr., Insp. Supervisor

An OEM tier 1 supplier of precision injection molded thermal plastic parts.

Perform Internal Audits, create Process Flow Diagrams, write (PCP) Quality Control Plans, write FMEA’s, develop Corrective Action Preventive Action (CAPA), establish GR&R Studies.

Implement a Statistical Process Control (SPC) program and instruct all employees to use SPC.

Establish the first GM Hydromantic Division self-certified incoming raw material laboratory to analyze physical properties of supplied materials. Write Lab Test Procedures, instructions and train the staff.

Participate in accomplishing a Best in Class rating with Ford. Writing work instructions and procedures.

New part layouts and write (ISIR) Initial Sample Inspection Reports and PPAP packages for customers.

Establish a Quality System to track and display Process Parameters and Statistically Monitor the Performance of Injection Molding Machines. Direct the activities of the staff of inspectors.

EDUCATION

150 total credit hours - More than Bachelors equivalent with over 30 years’ experience in quality

Indiana University, South Bend, IN - Pursuing BA Degree in General Studies, (20 hours for completion)

Computer Programming, Business Law, Political Science, Sociology

IVY Tech, South Bend, IN - Statistical Process Control

Purdue University - North Central, Westville, IN – Major, Electronics Engineering, Math

Trine University, Angola, IN - Degree: Associate in Applied Science Degree

- Major, Machine Design Technology - Minor, Production Management

References provided upon request

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