Quality Engineer /Manager

WALLACE J. KENSY http://www.linkedin.com/in/wallykensy

*** ****** ***** *****: 716-***-****

Tonawanda, New York 14150 *******@*****.***

PROFILE:

Quality Engineer proficient as a Continuous Improvement Leader with proven results through use of Kaizen, Six Sigma, Lean, & TQM principles. Highly effective in the organization and direction of cross-functional teams that produce product improvements and cost reductions. Responsible for supplying Quality Products to Fortune 500 companies such as Ford & Honda.

 Implemented and managed “Dings and Dents Scrap Reduction”, a company wide Kaizen project for a major automotive customer resulting in $250,000 savings.

 Leader of company Scrap Elimination Team with annual improvements of 10%.

 Investigated and implemented process changes to resolve major customer complaints, resulting in a 0% recurrence rate.

 Certified Six Sigma Black Belt through John Lupienski Senior Master Black Belt Applications & Training.

 Created and conducted quarterly Upper Management Review Meetings resulting in

effective communication of improvement efforts.

EXPERIENCE:

McGard LLC, Orchard Park, NY 2004 - 2009

Manufacturer of High Quality Security Products.

Quality Engineer

Led cross-functional team efforts to eliminate scrap and improve product output. Created data collection systems and effectively communicated all improvements through easy to read reports. Conducted departmental audits per ISO/TS 16949:2002 and ISO 9001:2000. Trained employees on problem-solving techniques. Responded to customer needs as related to product quality.

Selected Accomplishments:

• Presented “Dings & Dents Scrap” Kaizen program, as a featured speaker, at the American Society for

Quality’s 1st annual conference in 2008 that was highlighted in a Buffalo News article headlined,

“Collins sees Six Sigma program as key to growth in Erie County”.

• Prepared / presented detailed quarterly reports on scrap reduction progress to senior management,

satisfying ISO 9001:2000 & TS 16949:2002 requirements for Continuous Improvement.

• Achieved a 10% PPM reduction by focusing on two problematic situations each year. This resulted in savings of $100,000 + annually.

• Reduced product defects by 75% resulting in a continual strengthening of supplier & customer

relationships. Tracked data, raised awareness & implemented mechanical improvements.

• Sustained a 98% customer satisfaction rating with quality parts delivered on time, as member of internal auditing team that maintained strict use of Level 3 work instructions.

• Trained shop-floor staff to integrate with all other staff that successfully enabled Continuous Improvement Processes. Utilized problem solving tools such as: Story Boarding, Fishbone Diagrams, 5S Concepts, and Process Flow Diagrams.

• Implemented Lean concepts in Special Products Division, resulting in a 4-person continuous flow line that produced 2,000-units/per week (a 50% production increase) and met all customer requirements.

• Developed effective shop floor / office staff cross training and job swapping program that fostered increasing employee contributions in areas of process improvement, higher productivity and cost reduction.

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WALLACE J. KENSY

http://www.linkedin.com/in/wallykensy

EXPERIENCE (cont’d)

FEDCO Automotive, Buffalo, NY 1992 – 2003

Manufacturer of copper/brass and aluminum heater cores for the OEM and aftermarket.

Quality/Process Engineer (1995 - 2003)

Administered reports depicting monthly productivity and quality results in copper and brass divisions. Responded to customer concerns including on-site visitations. Assisted production personnel with an emphasis on loss and cost of quality.

 Assisted QA Manager with ISO-9001 certification process.

 Prepared Level 3 Manual for shop floor instructions.

 Served as engineering representative at national and regional trade shows.

 Provided supervisory support in shipping, production, quality assurance, and scheduling.

Total Quality Management Facilitator (1992 - 1995)

 Led cross-functional teams in continuous improvement process.

 Directed team objectives centered on working toward and achieving measured results in the areas of cost reduction, quality improvement, productivity, and customer satisfaction.

 Catalyst for instilling TQM culture and development of new team leaders.

 Developed and implemented award program for hourly employees who excelled in productivity and quality initiatives.

 Designed and implemented FEDCO’s TQM program to companies in Western New York.

EDUCATION:

Buffalo State College, Buffalo, NY

BS Industrial Technology

PROFESSIONAL DEVELOPMENT:

Kaizen Training, Toyota Motors, Chicago, ILL

Kaizen Principles, 2007

Six Sigma Applications and Training, ASQ Buffalo, NY

Black Belt Trained, 2005

Western New York Technology Development Center, Buffalo, NY

Lean Manufacturing, 2002

Dale Carnegie Institute, Buffalo, NY

Public Speaking, 1997

Ernst & Young, Buffalo

TQM Principles 1995

AFFILIATIONS:

American Society for Quality

Member, 1992 – Present

United Way of Buffalo and Erie County

Loaned Executive Volunteer

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