Quality Engineering/Manager

DUANE W. RAINEY

Phone: 248-***-**** email: *********@***.***

OVERVIEW:

Many years of experience in the Quality and Engineering Industry, which involved Six Sigma concepts and Lean Manufacturing, Progressive positions include Program Manager, Quality Manager, Sr. Quality Engineer, Supplier Technical Assistance Engineer, and Supervisor for Advanced Manufacturing Engineering, Quality Engineer, and Systems Analyst for major Automotive (Ford, General Motors, and Chrysler), Manufacturing, and Financial Firms.

EDUCATION:

Masters of Science Degree – Computer Information Systems – Jan 2002

University of Detroit – Detroit, MI

Bachelor of Science Degree – Computer Science/Math – May 1986

Marygrove College – Detroit, MI

Certification in Computer Technology – 1982

Control Data Institute – Southfield, MI

Green Belt Certification – Ford Motor Corp.

PROFESSIONAL EXPERIENCE:

Philips Healthcare Medical Systems, Albany, NY (Special Assignment, 30 Day Contract) 09/19

Supplier Quality Engineer

Facility was focused on MRI products/ components

Responsible for consulting with suppliers, certifying that products were built at run-at-rates specified

Worked through CAPA/ NCs

Stryker Operations, Kalamazoo, MI

Sr Advance Operation Manufacturing Engineer (contract) 10/20 – 8/21

Worked with Cross-functional team to design/develop manufacturing Process Flow for CT build

Lead development of manufacturing process for CT Scanner

Develop Manufacturing Phase #1 Process Failure Mode Effects Analysis (PFMEA) document

Worked with Product Eng. to develop Manufacturing Phase #2 (PFMEA) document

Travel to Boston, Mass to benchmark present CT manufacturing process and transfer tribal knowledge in new manufacturing plant.

CER 3rd Party Containment 01/19 – 10/20

Quality Supervisor/ Consultant

Work with several Manufacturing Plants leading a team of inspectors with containment

Work with team members in developing inspection methodologies when the OEM team did not have a Robust Quality Operating System in place.

AAM, Hamtramck, MI 09/17 – 10/18

Supplier/ Development Quality Engineer (contract)

Work with Suppliers in developing PPAP’s for carry over and new model parts

Visit Supplier plants train/coordinate closing issues on PPAP requirements using 4-Square

Work with AAM plants/ Suppliers during APQP process; finding root cause when customer create PRR

Work with Suppliers Developing Poke- Yokes with issues concerning non-conforming parts

Visit Suppliers to complete open (8D) corrective action reports & conduct Inventories reviews

Ability to conduct VDA 6.3 audits when Supplier are required to complete annual audits

Travel to Supplier sites and review Proprietary/ Confidential information when required

Adient, Plymouth, MI 09/16 – 08/17

Customer Advance Quality Engineer (contract)

Work with the General Motor’s Business Unit to ensure all issues pertaining to the 2018 Alpha Program requirements are completed.

Track and monitor all APQP issues with Supplier to ensure they are completed.

Work with Engineering to ensure IMDS requirements are completed.

Track Supplier to Adient/JCI PPAP, BWI/Adient/JCI plant to schedule GR&R, Run @ Rates, and Product test are completed.

Webasto Roof Systems Inc., MI 09/14 – 09/16

Supplier Development Engineer (VDA 6.3 Auditor)

Travel weekly to supplier for status reviews to Develop & Track Improvement Plans

Lead cross-functional team in development/improvement process

Work with supplier’s in developing/improving their manufacturing process

Create Parato’s & Conduct reviews for non-conforming issues

Conduct VDA 6.3 Process Audits track/ New Supplier Potential Analysis Qualification Audits

Create Parato for repeat defects and establish corrective actions

Establish Dashboard Metrics and present to upper management

Tracked monthly On Time Performance (OTP) & (3) Months Rolling Avg. for OTP

Tracked Quality defects & Cost of Poor Quality

Lead weekly meeting for Open Order Reports (OOR) & Supplier Corrective Actions Reports

Weekly review of IATF metric and Continuous Improvement activities with Suppliers

Conducted Engineering Change Notice(ECN) with Webasto & Suppliers

Detroit Thermal Systems, Romulus, MI 02/14 – 08/14

Warranty Quality Engineer (contract)Commodity Injection Molding

Work with present QM developing Service Parts Process using Injection Molding Systems

Work with Customer in developing warranty tracking system

Work with Supplier Quality Eng. and team members testing and tracking Warranty concerns

Develop Layered Process Audit (LPA) documents/system

Train Team Members, Supervisors, Engineers, and Management Staff on (LPA) process

Prepare annual Quality System Audit plan/schedule

Developing/Maintaining Quality Operating System & Standardized Work Instructions

Assist manufacturing operation to establish quality requirements for New Programs

Help Develop personnel requirements for starting/adding quality on all shifts

Supervise/Lead problem solving activities for personnel on both 1st, and 2nd shift

Enova Premier of Alabama 09/13 – 01/14

Quality Engineer Manager (contract)

Report to the VP of Operations with (1) direct report and (6) indirect reports

Tire & Wheel Assembly process customer Hyundai Motor Manufacturing of Alabama.

Work with present QM developing management skills

Lead TS 16949, QS 9000, ISO 14001, and certifications

Prepare annual Quality System Audit plan/schedule

Developing/Maintaining Quality Operating System & Standardized Work Instructions

Worked with Operation Manager developing objectives & goals for manufacturing operation

Lead manufacturing operation to establish quality requirements for all business relationships

Liaison in channeling customer direction regarding quality requirements

Develop personnel requirements for starting an additional shift

Supervise/Lead problem solving activities for personnel on both 1st, 2nd, and 3rd shift

Johnson Control Inc., Plymouth, MI 09/12 – 09/13

Sr. Advance Supplier Quality Engineer (contract)

Develop new department for Advance Supplier Quality Engineers

Establish metrics, process, and PPAP requirements for Tier 1 Supplier’s and department

Sign-off on Tooling, Gauge Design/functionality, and Process capability studied.

Determine frequency for supplier Audits, Reviews and PPAP requirements.

Develop/determine how suppliers/commodities will be distributed among Engineers.

Supported/Lead the APQP Process as well as the Launch Readiness Reviews (LRR) for Injection Molding, Weir, Formed Parts, and Machining Suppliers

ITT Gould’s-IP, Seneca Falls, NY 08/11 – 08/12

Supplier Development Engineer (contract)

Lead/Develop Supplier’s to Gould’s in Central Region of US (Illinois, Wisconsin, Mich., Ohio)

Travel weekly to (7) supplier for status reviews to Develop & Track Improvement Plans

Lead cross-functional team in development/improvement process

Work with Casting supplier’s in developing/improving their manufacturing process

Create Parato’s for Patterns that produce non-conforming castings

Conduct pattern review for non-conforming pattern

Create Parato for repeat defects and establish corrective actions

Establish Dashboard Metrics and present to upper management

Tracked monthly On Time Performance (OTP) & (3) Months Rolling Avg. for OTP

Tracked Quality defects & Cost of Poor Quality

Lead weekly meeting for Open Order Reports (OOR) & Supplier Corrective Actions Reports

Weekly report to ITT management OOR and Quality concerns

Conduct New Supplier Qualification and Internal Audits

Conducted Engineering Change Notice(ECN) with ITT & Suppliers

L & W Engineering, Belleville, MI 03/11 – 05/11

Advance Quality Engineer (Contract)

Launch New Manufacturing Process for General Motors Programs

Develop Process Flow Charts, Control Plan, PFMEA, and GP-12 shipping

Track Quality Performance for manufacturing operation, as well as customer complaints

Collect data and create charts to determine negative and positive trends

Certified Checking Fixtures for new process

Tracked Engineering changed on Dies as well as Checking Fixtures

Worked with CMM Programmer and Program Manager to establish check points off Drawings

Worked with Manufacturing to ensure process capability

Worked with customer/team to ensure the APQP process was being followed, tracked, and approved

Tracked IMDS changes with the Material Department

Reviewed and approved Tier #2 Supplier’s PPAP’s

Developed corrective action plans to reduce RPN ‘s

Tracked RPN reduction process for several different programs

Documented and tracked Weld Validation process capability

Worked with production in developing Golden and Master parts for new programs

Act as Liaison between Customer and Manufacturing Plants

Lead internal audit process and identified /tracked/monitored any non-conformances

Develop and Track employee training matrix for manufacturing plants

Schaeffler Group, Cheraw SC 08/10 – 02/11

Group Quality Team Leader (Acting Quality Manager)

Reported to Segment Leader with (14) direct reports

Launched New Manufacturing Plant for Multi-Air Actuator in 8 months

Responsible for machine capability studies/ developing dFMEA and pFMEA, GD&T, etc.

Responsible for hiring and directing entire quality department

Lead plant ISO/TS 16949:2009 requirements, SPC, AIAG-APQP, PPAP, FMEA,

Travel to several locations in Germany (Ingolstadt, Magdeburg, Hershaid, Hertro) to study the manufacturing and quality process of the Multi-Air Actuator

Traveled to the Czech-Republic to help Tier 1 supplier develop their manufacturing process and understand the concept of using SPC to track CC’s and SC’s on the print

Traveled to several Suppliers in Germany to verify a robust manufacturing process capability

Worked with Tier 1 Suppliers to develop a data collecting process for SPC

Worked with several Suppliers in Analyzing, Organizing and Interpreting data

Developed action items when data reflected negative trends

Reviewed data gaps and negative trends with team and upper management

Lead team in finding root cause of data trends and assigned projects to base on data trend findings

Develop gauging process for checking the machined and functionality of actuator

Met with Zeiss, CMM manufacture, to develop program for verifying quality of machining process

Worked with Plant Engineer to determine design for CMM clean room

Develop Control Plan, and PFMEA from Germany process to operate in North America

Develop Process Flow charts for quality checks as well as problem solving tools

Developed and implemented SOPs for personnel

Worked with team to establish and order equipment for Cleanliness and Contamination lab

Experience in the manufacturing of valves and/or pumps reacting to electrical signals

Experience with six-sigma problem solving (Green Belt)

Lead process for collecting data to support ISO 14001, and Q1 certifications

Medtronic, Memphis, TN 05/10 – 08/10

Sr. Quality Engineer (Contract)

Support Production Manager with production development

Participate in Design Control Project providing Quality Engineering support

Serve as an independent reviewer on all assigned projects ensuring that design history files comply with company policies and government regulations

Review, approved drawings, ECR, and evaluated quality requirement

Correct application of GD &T, proper use of process and material specification and key characteristics for inspection plans a gauging technique.

Develop inspection techniques includes identification of characteristics, sampling plans, and gauging

Recommend gauging techniques: develop gauging work instructions

Assure GR&R are results through the use of statistical techniques

Use quality tools to implement improvements: Process Flow Charting Pareto Analysis, Correlation/ Regression analysis, DOE, SPC, GR&R, and Trend Techniques

Assist Suppliers with the interpretation of quality requirements

Develop C P that identify inspection characteristics, gauging techniques, and sampling requirements

Assist the design control project team with the development of essential design control deliverable with the use of complaint analysis on similar products, risk analysis, FMEA, essential requirements check list, and design verification/validation

Assist with internal and external quality audits and inspections

BorgWarner, Water Valley, MS 09/09 – 03/10

Sr. Contamination Quality Engineer (Contract)

Reported to the Quality Manager with (3) indirect reports

Transmissions Modules

Brother Industries (USA), INC., Memphis, TN 04/08 – 07/09

Supplier Quality Engineer (Contract)

Completed line transfer of ‘Excalibur’ printer from Bristol, CT to Memphis, TN over 12 months

After completion, transferred same line to China

Responsible for recreating control plans, pFMEA, run rate testing, quality testing, sound testing, etc.

ISO 9000 regulated environment

Reported to the Quality Director with (6) indirect reports.

Copier, Printer, Sewing Machine, and FAX Machine manufactures

Gulf Shore Assemblies, Lincoln, AL 09/07 – 04/08

Quality Manager (Contract)

Reported to the Plant Manager with (3) direct reports and (6) indirect reports in a facility of (60) employees.

Tire & Wheel Assembly process customer Honda Manufacturing of Alabama.

Carrier Corporation, Collierville, TN 09/06 - 08/07

Sr. Quality Engineer

Reported to the Quality Manager with (4) direct reports and (12) indirect reports in a facility of (2400) employees.

Employer was Carrier Corp. who manufactured and assembled Heat Pumps and Air Condition Units.

T&WA of LANSING, Lansing, MI 06/02 – 09/06

Program Manager (Promotion)

Reported to the Director of Operations with 4 direct reports, and 5 indirect reports in a facility of 100 employees.

Tire & Wheel Assembly process main customer’s Ford and General Motors Manufacturing Corp.

Quality/Engineer/ Manager

Reported to the Director of Operations with 4 direct reports and 5 indirect reports in a facility of 100 employees.

Ford Motor Company, Dearborn, MI 11/00 – 10/01

Supplier Technical Assistance Engineer (Promotion)

Reported to the Supplier Quality Manager, supporting the development of 6 Tier1 Suppliers, each supplier employing several hundred employees.

Each Tier 1 supplier manufactured, machined, and formed several different types of parts

DaimlerChrysler, Auburn Hills, MI 07/94 – 11/00

Supervisor for Advanced Manufacturing Engineering (Promotion)

Reported to the Dimensional Control Manager with 20 direct reports in a facility of several thousand employees.

DaimlerChrysler Body in White process, which developed and assembled prototype vehicles.

Quality Engineer

Reported to the Production Manager with 4 direct reports in a facility of 1700 employees.

Machined and Assembled the 45RFE Transmissions.

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