Engineer Quality

DANIEL R. RUPERS CSP

**** ******** ****** ****: 706-***-****

Hull, GA 30646 *********@*****.***

PROFESSIONAL COMPETENCIES

Highly versatile and experienced manufacturing and HSE professional leveraging strong interpersonal skills, flexibility, and teamwork to achieve customer satisfaction, cost savings objectives, reduced cost of non-quality, and a safe working environment. Over 16 years experience leading organizations in Quality, Safety, and Environmental management systems. Utilized 6 Sigma problem solving and lean manufacturing tools in chemical processing, automotive, and heavy manufacturing industries to reduce process variation, waste, and promote safety practices.

+ QS/ISO9001, TS16949, ISO 14001 + Safety Management Systems (OHSAS18001) + CSP Certification

+ Process Engineering and Continuous Improvement + Project Planning and Development + Team Building and Lean Mfg

+ Facility and Maintenance Management + 6 Sigma Problem Solving + Customer Relations

PROFESSIONAL EXPERIENCE

ARVINMERITOR, INC. COMMERCIAL VEHICLE SYSTEMS, Franklin, KY January 2010 - Current

Global supplier to the Automotive Industry with $12B in Annual Sales.

Facilities Coordinator – manage contractors and facilities staff in maintaining daily 5S activities, environmental controls, HVAC, and building/production processes. Responsible for improving reliability of facility systems.

+ Review historical downtime failure causes on critical assets and re-write preventive maintenance work instructions to increase mean time to failure

+ Implement photo detection circuit on over-head cranes to eliminate damage to rope caused by slack rope.

+ Responsible for 100% on time completion of facility PMs.

+ Manage contractors and implement 5S projects

POWER PARTNERS, INC. Athens, GA 2007- September 2009

Global supplier to the power transmission, solar collector, and commercial chiller industries with $200M in annual sales.

Quality Manager

Direct supervision of 3 engineers and 5 technicians, driving plant-wide continuous improvement activities.

+ Employed cross functional teams to develop and implement 2 nationally acclaimed plant-wide Behavior Based Quality (BBQ) processes that reduced end of line defects by 47% and test failures by 39%, yielding $95K in savings. Reduced wire scrap by $65K.

+ Reduced steel scrap COPQ from 1.05% to .95%, saving $40K in steel scrap.

+ Installed automated coil winding equipment to reduce wire scrap by $65K.

+ Reduced paint defects by 20% on E-Coating process through control charting of key process parameters, reducing rework costs $539K.

+ Increased powder paint process FPY from 72% to 92%, reducing $10K in rework costs.

+ Led DOE/6 Sigma team eliminating the #1 Pareto defect in tank fabrication improving process capability improving FPY from 67% to 93%, reducing rework costs by $113K.

+ Using APQP, championed start up of 2 new products.

ARVINMERITOR, INC. COMMERCIAL VEHICLE SYSTEMS, Franklin, KY 2002-2007

Global supplier to the Automotive Industry with $9B in Annual Sales.

Manager of Safety and Quality, (2005-2007)

Promoted from Facilities Engineer to Manager of Safety and Quality. Strategically employed the quality management system to improve manufacturing processes and customer satisfaction. Developed 4 Quality Technicians and 1 Quality Specialist to incorporate quality and HSE processes into daily operations to achieve quality and HSE goals.

+ Exceeded cost of non-quality targets while producing at 28% above AOP.

+ Mentored Site Safety Steering Team and Quality Technicians to focus on supporting work area 5S organizational systems. Highlighted non-quality and safety action item costs using continuous improvement processes; reduced machine scrap from .29% to .22%, saving $80K.

+ Promoted process improvements which reduced coolant and hydraulic oil usage by 20%, and reduced raw material usage by recycling of metal chips, saving $600K.

+ Implemented infrared data collection and visual display of foundry casting process on target for 50% scrap reduction through improved process feedback to operators. Reduced burden by $55K.

+ Received KYOSHA commendation for engineering control of crystalline silica in foundry, reduced labor costs $55K.

DANIEL RUPERS Page 2

PROFESSIONAL EXPERIENCE (continued)

Facilities Engineer, Franklin, KY (2002-2005) - Plant responsibility for HSE, Facilities, and Process.

+ Managed and let facility-wide programs to achieve Safety Management Certification (OSHS18001) and established the FOCUS+ behavioral based safety process. Reduced OSHA recordable injury rate from 18 to 1.9.

+ Initiated site Ergonomics Team to address top Pareto injury causes leading to improvements in machine guarding. Reduced foundry related injuries by 90%, reduced recordable eye injuries by 90% and hand injuries from 12/yr to 1/yr.

+ Led Franklin facility to ISO14001 registration. Achieved certification and developed annual safety and environmental targets for the facility. Team members absorbed safety and environmental outsourced tasks leading to annual cost savings of $12K. Implemented internal recycling of scrap materials that resulted in $1.2M in 2006 raw material cost savings.

+ Received Chairman’s Silver Quality Award for reducing foundry scrap by 7% = $40K.

VALSPAR CORPORATION, INDUSTRIAL DIVISION, Bowling Green, KY 1999-2002

Global Producer of Coil Coatings with $3B in annual sales.

Process Engineer – Responsible for Process and site HSE activities for the Bowling Green facility and promoted to Corporate HSE role.

+ Ran DOE to address color matching issues, developed standard work and reduced customer color match complaints 45%.

+ Championed Safety Team activities and developed team member behavioral safety systems. Implemented DuPont STOP safety process. Teams Developed and conducted facility-wide root cause analysis training.

+ Led Site Safety Steering Team through implementation of OSHA Process Safety Management. Included: Job Safety Analysis, Hazards Operability Studies, and P&ID managed systems. Trained site personnel in safety design and environmental compliance, and management of change requirements for all capital projects.

+ Title V permitting and compliance, OSHA, RCRA, HSWA and Waste Management, NPDES and Industrial Wastewater permitting and compliance, EPCRA record keeping and reporting, TSCA, DOT and SPCC. HAZWOPER 40 Hour, RCRA and DOT

LILLY INDUSTRIES, INC., Bowling Green, KY 1996-1999

Supplier of Industrial Coatings with $700M in annual sales.

HSE/Plant Engineer, (1997-1999) – Process Engineering and site HSE Coordinator

+ Achieved QS9001 certification and developed level 2 and 3 QS documentation.

+ Developed and implemented a hazardous waste management program that established a 10% reduction trend with hazardous waste at a 30% annual increase.

+ Led the transition team for small ingredients dispensing system designed to support the large batch process. Designed functional specification, system integration of PLC controls ensuring compliance with air permitting requirements and eliminating operator exposure to hazardous chemicals.

+ Developed safety and environmental training and certification systems for in-house safety team members

including: tow motor safety, first aid and CPR, safety and housekeeping inspections, and corrective action plans.

Safety Team absorbed periodic environmental inspections, tow-motor inspections and maintenance, and shift startup housekeeping plan. Reduced outside contractor costs $20K.

EDUCATION AND TRAINING

B.S., ELECTRICAL ENGINEERING TECHNOLOGY, Western Kentucky University, Bowling Green, KY - 1995

Kentucky Advanced Technology Center, Bowling Green, KY – 1992

+ Applied 6 Sigma – DOE, SPC, RCA, QE, Lean Manufacturing + High Performance Work Team Certification

+ Mini Tab, MS Project, Visio + Hazardous Waste Management, HAZWAPER Cert.

+ Commercial Pilot License – multi-engine, instrument + First Aid/CPR/AED/OSHA 30 hr

+ CSP Certification

References and salary history available upon request

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