Quality Engineer Senior

GLEN H. SAEGER

Cell: 618-***-**** / Email: ************@*****.***

PROFESSIONAL SUMMARY

Experienced Senior Quality Engineer and Metallurgist with 20+ years in component manufacturing, APQP, and continuous improvement. Expert in IATF 16949, AAR M-1003, SPC, and Six Sigma methodologies. Proven ability to lead cross-functional teams, drive process improvements, and manage new product launches.

CORE COMPETENCIES

Quality Systems: ISO/TS16949, IATF 16949, AAR M-1003

Continuous Improvement (CI) & CAPA

APQP & PPAP

Lean & Six Sigma (Green Belt Certified)

Root Cause Analysis / 8D

Gage R&R / SPC / DOE / ANOVA

Metallurgical & Mechanical Testing

Minitab, SAP, Excel (advanced)

EXPERIENCE

OPW Midland Manufacturing – Chicago, IL

Senior Quality Engineer 2019-Present

Implemented and maintained a gage control software containing over 3,500 gauges.

Project manager for transitioning from an outdated gage control software to a modern software program.

Created an NCR database in SHAREPOINT for tracking and reporting of customer, supplier, and internal quality problems.

Issued NCR’s for internal nonconformances.

Issued supplier nonconformance report to suppliers.

Processed and reviewed customer returns.

Lead root cause and prevention problem solving for warranty investigations.

Reduced assembly challenges by recommending coating change on a screw.

Trained employees to quality procedures and plant work instructions.

Made recommendations for improvement to quality procedures and plant work instructions.

Performed internal quality compliance audits.

Responsible for PPAP data review and submissions.

MRB analysis and dispositions of nonconforming product.

Maintained AAR M-1003 quality requirements and certification.

Chicago Powdered Metal Products – Chicago, IL

Senior Quality Engineer 2018-2019

Supported IATF 16949 and General Motors BIQS audits / certifications.

Supervised non-exempt quality team.

Created versatility matrix and cross training plan.

Collaborated with operations to assure quality coverage.

Project manager for internal and external quality concerns.

Reported containment and CAPA progress on customer portals.

Implemented FAST RESPONSE matrix. and tracking.

Compiled data and tracked quality KPI’s: scrap, open concerns, first pass yield, and containment activities. Supported value stream engineers with practical problem-solving techniques, verification of CAPA effectiveness, standard work, and lessons learned.

Created real-time data tracking files used to pareto concerns and drive continuous improvement activities related to scrap.

SSI Technologies – Sintered Specialties Div. – Janesville, WI

Quality Engineer – New Product Launch Team 2017-2018

CAPA champion for all new business in VVT / VDVP family (cam rings, vane rotors, slides).

Fulfilled APQP responsibilities for VVT / VDVP components.

Coordinated PPAPs – PSW, PFMEA, control plan, MSA, capabilities, material validation

Trained machine operators in 1-piece flow concepts and importance of standard work.

Used Minitab statistical tools to compare various processing methods.

Improved Ppk for a critical feature of a pump slide from 0.3 PpK to 1.67 PpK, by analyzing data and providing recommendations to the tooling design group.

RPN Reduction - Developed a gaging solution which improved inspection time for customer critical features by 85% (1/7 original cycle time), while improving detection confidence.

ZF - Division TE / Active & Passive Safety Technology – Lebanon, TN

Senior Quality Engineer & Metallurgist 2015-2017

Member of team for IATF-16949 risk (gap) analysis and implementation.

Managed transition from 100% captive heat treatment to 100% outsourced heat treatment by coordinating activities between suppliers, Supplier Development Engineering, Product Engineering, Plant Operations, and Plant QC staff.

Advised suppliers on development of PFMEA, control plans, and inspection instructions.

Participated in focus groups to achieve IATF16949 / ISO conformance.

Implemented a system for tracking test cell variability and trends which helped predict test cell reliability problems before breakdowns. Examples: failing pumps, incorrect data collection rates, worn / slipping chuck jaws, oil cooler problems.

Implemented statistical process control (an untouched concept for this facility) in one of the critical cells for which I was responsible.

Improved gaging and data collection systems for critical machined features of the worm screw valve. -Gage R&R, decision making matrixes, ANOVA.

$150k annual scrap reduction on the worm screw using gage R&R and regression analysis, and processing of test failures.

UNIPRES, NA - Portland, TN

Quality Engineer 2014-2015

Timely response to customer complaints and 8D reporting, as an automotive Tier 1 and 2 supplier.

Identified areas for improvement of quality, cost, and productivity.

CUMMINS, INC – Columbus, Indiana

Plant Metallurgist 2011-2013

Managed lab operating budget and identified staffing needs.

Monthly reporting of lab measures: expenses, lab throughput, and cycle times.

Completed two 6-Sigma green belt projects under the Cummins certification program.

Performed failure analysis and wrote technical reports to document failure modes and root causes for engineering, new product development, and service engineering.

Identified a materials engineering solution for fuel spray nozzles which improved engine performance and customer satisfaction.

PMG-INDIANA CORPORATION – Columbus, Indiana

Quality Engineer / Manufacturing Engineer 2013-2014

Product Engineer / Metallurgist 2000-2011

Operated in several engineering capacities: Product launch / APQP, tool design, CAPA reporting, quality, continuous improvement, manufacturing engineering.

Coordinated PPAP of $30M fully automated production line.

Reduced scrap cost by 30% by publishing standards and work instructions.

Led a $240k cost savings by reducing the defect rate from 7% to 1% on $4.1M annual revenue.

Performed product launch (APQP) activities including: feasibility and contract review, process capabilities, PFMEA, process flow, gaging, and control plan development.

EDUCATION

MISSOURI UNIVERSITY OF SCIENCE & TECHNOLOGY

Rolla, Missouri

B.S. Metallurgical Engineering

Contact this candidate