Senior Quality & Safety Engineer - Global QC Leader
Resume:
David Mace
980-***-**** • Concord, NC 28027 • ******@***.*** • linkedin.com/in/david-mace-5b4a8b36a SUMMARY
Results-oriented professional with experience in implementing manufacturing plant improvements, managing risk, quality assurance, quality control, and safety management EXPERIENCE
Pyrotek Inc. - Manufacture of consumable components for the aluminum, foundry, steel, and glass industries Salisbury, NC
SENIOR USA QUALITY & SAFETY ENGINEER
September 2013 – June 2025
Responsible for 13 plants in 3 countries
Managed the KPI program that improved operations and formalized competition between plants
Reduced lost-time incidents from 12 per year to 4 per year; a 75% reduction
Reduced the number of defects that reached the customer from 1,009 DPPM to 29 DPPM; a 97% reduction
Reduced Scrap as a Percent of Cost of Goods Sold from 4.19% to 0.08%; a 98% reduction
Increased On-Time Delivery from 84.9% to 97.1%; a 14% increase Wrote safety procedures, led safety committees, investigated accidents, implemented safety preventive measures, championed engineering process modifications to reduce injury exposure to associates. Product Planning: Reviewed requests for part quotation for safety concerns, new product risk management, Advanced Product Quality Planning (APQP), Failure Mode and Effects Analysis (FMEA), Statistical Process Control
(SPC), Quality Control (QC), and Production Part Approval Process (PPAP) submission requirements. Documented processes and control plans for Quality Assurance (QA) Reviewed requests for quotations to identify quality concerns and product risks Analyzed production data, compiled statistics, used data to identify issues, determined the root cause, proposed corrective action, implemented solutions, and evaluated the effectiveness of actions Led Root Cause Analysis (RCA) investigations for safety incidents, scrap minimization, and Corrective Action (CA) Led Preventive Action (PA) and Continuous Improvement (CI) projects that met Return on Investment (ROI) requirements
Managed the ISO 9001:2015 Quality Management Systems (QMS) for 12 sites, 3 certificates, in 3 countries Conducted ISO 9001:2015 Internal Audits, Safety Audits, Layered Process Audits, and audited sites to current Good Manufacturing Practices (cGMP)
Collaborated with cross-functional team consisting of customers, suppliers, manufacturing teams, process engineers, product engineers, sales personnel, and management Experienced Minitab user
Traveled domestically and international
Managed 4 Site Quality Representatives and 17 Quality Technicians Quality Management Tools used: 8-D, FMEA, SPC, MSA, Pareto Charting, 5-Why, Ishikawa / Fishbone diagram, Flowcharting, Histogram, Strength / Weakness / Opportunities / Threat (SWOT) Analysis, Control Charts Fiberon – Manufacture of outdoor decking and components New London, NC
Quality Engineer
September 2009 – August 2013
Responsible for product quality at two plants
Implemented a product quality Statistical Process Control (SPC) program Trained associates to make machine adjustments based on the use of SPC charts Oversaw a capital project that added in-line optical defect detection and containment system on production lines Developed testing protocols for decking products and railing systems Led Lean Manufacturing projects, Kaizen Events, 5S projects, and three (3) six-sigma projects - Savings $4.7M with a 5-person team
David Mace – page 2 of 3
Performed incoming inspections, in-process inspections, finished product inspections, and issued certificates of conformity
Performed testing & part inspections using CMM, calipers, and gages Responsible for the work of 20 Quality Inspectors
Microban International – Antimicrobial solutions provider Huntersville, NC
Quality Manager
June 2003 – August 2009
Protected the Microban Brand
Managed the Quality system
Tested customer's parts for proper dosing level per contract
Independent Contractor, Part Time September 2002 – June 2003 Led the organization to ISO 9001:2000 certification The Polymers Center (TPC) – Research facility for the plastics industry Charlotte, NC
Independent Contractor, Part Time
October 2001 – June 2003
Learned about plastic compounding, extrusion, injection molding, and lab operations in exchange for implementing ISO 9001:2000
TPC arranged for me to work for their customer Microban in the afternoons; September 2002 – June 2003 Corning Incorporated – Manufacture fiberoptic glass Midland, NC
Contractor
April 1999 – September 2001
Managed the installation of extrusion equipment on draw towers Assisted with the introduction of the On-Draw Screening (ODS) System Trained associates to use the equipment
Hitachi Metals NC – Ferrite magnet manufacturer
China Grove, NC
Process Engineer
September 1992 – January 1999
Made process improvements to magnet grinder equipment Performed product changeovers
Trained associates to operate equipment
Department of Defense
Fort Bragg, NC
Management Analyst, GS 5 - GS 11
September 1983 – August 1992
Audited base services
David Mace – page 3 of 3
EDUCATION
Campbell University
Masters • MBA
August 1985 – December 1987
Graduated
North Carolina State University
BS • Mechanical Engineering
January 1989 – December 1992
Graduated
North Carolina State University
BA • Business Management and Economics
September 1980 – June 1983
Graduated
LICENSES & CERTIFICATIONS
ISO 9001:2015 Internal Auditor
SAI Global • C273420
Six Sigma Black Belt
Skillsoft • LHH8514
Manager of Environmental Safety and Health
North Carolina State University
OSHA 30 Hour General Industry Safety & Health Course North Carolina State University • 900096175
Engineer In Training
North Carolina State Board of Registration for Professional Engineers and Land Surveyors • A-14863
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