Quality Manufacturing Engineering

Quality Assurance/Manufacturing &

Production Coordination

Bring my expert knowledge in all aspects of the TOYOTA Production System: Quality, Cost and Delivery. Kanban, 4s, 4m (Ishikawa diagram), SMED, heijunka, jidoka, pokeyoka, standardized work instructions (pre-ISO), supply chain management to your company.

I have over 15 years with this method (9yrs) with TOYOTA. I have used these methods within a team oriented environment in start-up companies, established firms for both high and low volume production runs. I have experience in using these systems in Asia and Europe. I thrive on challenges and project management, and working by consensus in a group environment. I have never failed in this area of endeavor. I have SPC (pre-six-sigma) and have conducted seminars in the six-step TOYOTA Problem solving methods and have used them extensively in my career.

My experience & expertise includes:

All Windows software & graphics

TOYOTA Six-Step Problem Solving seminars

Computerized ordering and delivery systems (KanBan)

All aspects of world class manufacturing systems (TOYOTA Production System)

Pre-Production Planning & Scheduling

Production Planing

Published book “The Symphony of Manufacturing” & conducted seminars on world class manufacturing systems

Knowledge/Understanding of Government Standards for MIL and FDA products

ISO 9001 Coach for 1994 & 2000 Guidelines

Internet user (15 years)

Manufacturing Processes:

Ferrous Metal production-Mining, processing, coke ovens, metallurgy, grades metals

Non Ferrous Metal production- Mining, processing, grades, metallurgy

Stamping, forging, and forming (Single Minute Exchange Die Change SMED idea)

Machining, CNC, 4 axis & 3 axis

Spinning & forming

Extruded Metals (Wire Forming)

Plating & Anodizing,

Painting & Powder Coating

E-Coat

Secondary operations-sub assemblies

Air gun & impact torque asm & tests

Plastics-Injection Molding

Tooling Design

Tooling Engineering

Manufacturing Processes (cont’d):

Material grades

Gas Injection Molding

Quick Change (Gibbs System & MUD)

Thermoset Materials

Rubber Materials-EPDM

Control Process & Change Plans

Electronic Assemblies & processes (IPC-610)

Ultrasonic Cleaning & Assemblies

Piezoelectric Ceramics

Sonic Data & Investigations

Light Quanta & Data

Glass Manufacturing & Data

Lamp Manufacturing & Data

NASA –one-of-a-kind-products

EMPLOYMENT HISTORY

10/1994-Present Self-Employed Contract Engineer

Oakland Consulting Group (General Manager)

North East (Erie), PA

Any manufacturing engineering issues, start-up operations, bring new products to mass production readiness, production preparation, system review. Automotive applications, APQP, PPAP, FEMA, MIL applications, FDA & UL regulations and quality requirements, first article, introduction of lean manufacturing systems, and TOYOTA principles.

2/2009-6/2010 Quality Coordinator (Contract Engineer)

FMC-Erie (Smith Meter) Erie, PA

REPEAT CLIENT

• Introduce Parts & Supplier Qualification for supplier parts (over 400 part numbers approved in 1yr)

• Solve mfg issues from MRB data

• Solve supplier issues from MRB data

• Issue ECN for mfg and supplier parts as needed.

• Coordinate quality/mfg issues between purchasing, mfg, quality & engineering for solutions (problem solving)

• Created and implemented Quality System for First Article Inspection

• Created computerized system for tracking defective parts and counter measures

• Created and implemented computerized First Article Inspection Reports by supplier & part number

• Use TOYOTA methods for production and qualification of parts and suppliers

6/2008-8-2008 Terex Cranes (Heavy Equipment)

Contract Group Leader Final Inspection

(7 UAW t/m on 2 shifts)

Waverly, Iowa

• Completed SWS and cycle times for 4 models and service kits with 3 processes per model

While directly involved with coordinatingasm with final insp., set back to back monthly records for revenue and quality units delivered. July revenue and delivery broke previous 10 yr old record.

11/2007-1/2008 Valeo Industries (Contract- Kaizen Project Leader)

Advanced Mfg Engineering

Jamestown, NY

4/2007-8/2007 Bell Helicopter Textron (Texas) (Contract/PT)

Source Inspection/Audit

(Lord Corp)

Erie Area, PA

5/2007-8/2007 Rolls Royce Engine Division (Indianapolis, IN) (Contract/PT)

Production Control/Scheduling Specialist

Jamestown/Falconer, NY

7/2006-11/2006 Quality Assurance Engineer (Contract)

FMC-Erie (Smith Meter) Erie, PA

• Introduce Parts & Supplier Qualification for China supplier parts (over 70 part numbers approved in 3 months)

• Solve mfg issues from MRB data

• Solve supplier issues from MRB data

• Issue ECN for mfg and supplier parts as needed.

• Coordinate quality/mfg issues between purchasing, mfg, quality & engineering for solutions (problem solving)

• Use TOYOTA methods for production and qualification of parts and suppliers

4/2006-7-2006 Contract Engineer

LORD Corp, Rotary Wing Mechanical Products Section

Erie, PA

• Solve start-up issues for companies in engineering, quality & production control

• Systems review for start-up and beginning mass production item

• Production preparation prior to mass production, APQP, PPAP, FMEA, MIL-STD, FAA, Sirkorsky. Bell Engineering stds

• Use TOYOTA methods for pre-production/start-up issues

12/2005-2/2006 Contract Engineer (Oakland Consulting Group)

North East, PA (Grove City, PA & LaPorte, IN)

General Electric Transportation

Quality Engineer for locomotive diesel engine block

Source inspection for each cast engine block. Wrote cleaning standard for both GE & Casting Service as standard for shipment. Shipped over $800,000 in parts saving GE $20,000 in rework costs, due to written inspection standard for casting cleaning acceptance.

7/2005-9-2005 Contract Engineer (Oakland Consulting Group)

North East, PA (Indianapolis, IN)

International Truck & Engine

Quality Engineer for wire harnesses for diesel engines, current and future products. Saved over 30 engines from wrong configuration to Ford Motor Company. Coached suppliers in 6 sigma and Toyota problem solving methods.

8/2004-1/2005 Contract Engineer (Oakland Consulting Group)

North East, PA (Franklin, PA)

Approved 1st Articles on behalf of Franklin Bronze & Baldwin Hardware (Black & Decker Hardware Division, Harrisburg, PA)

Complete layouts, production processes and source approval

1/2004- 8/2004 Project Engineer/Management (Contract-Erie, PA)

Borg Warner Turbo Systems

Arden, NC

Quality, Production Planning, PPAP, APQP, FEMA, Supplier Quality Management

Completely responsible for multi-plant supplier machining operations (in PA) for

quality,production planning and start-up or transfer of new products, parts, processes to

new or existing suppliers. 7 months production 15-20,000 machined parts without

ONE REJECT.

9/2002 – 3/2003 International Configuration Manager

Pride Mobility Products (Electric Scooter and Power/Wheel Chairs)

Exeter, PA

Completely responsible for the configuration, specifications and sample orders for new model introduction. Liaison between purchasing, production control, quality engineering, and design for successful launch of new products to overseas locations. Coordinate new models with Canada and over seas locations in Australia, Japan, UK, Europe, Italy and other countries.

Work with all departments on resolving field issues on quality and delivery issues.

Confirm all issues/concerns are successfully addressed and solved before production begins at Asian manufacturing facilities. Confirm any engineering changes are communicated with foreign subsidiaries and implemented for resolution of problems and issues on any delivery, cost and quality items.

Assist in implementation of improvements (Engineering Changes) to existing products for international operations. Successfully launched multiple new product lines ($1,000,000) in Korea and China. Provide service and engineering assistance to Pride’s foreign subsidiaries for improvements of current products and development of new models for new and existing customers

8/2000-11/2001 Quality Engineer, Manufacturing Engineering & Production Control Specialist

Cybersonics/NUVO

5368 Kuhl Road

Erie, PA

Complete & total responsibility & authority for all quality issues for 2 start up companies

(less than 3 yrs old) of 20 people. Medial equipment (operating room lights and ultrasonic medial cleaning systems) Interface with design, customer, suppliers, and shop floor and president on any matters pertaining to problems in field, suppliers, and shop floor. Introducing ISO 9001- 2000 concepts for certification . Training in quality concepts, FDA, Kanban, JIT, kaizen, production control & scheduling and other world class competitive production concepts. Warranty issues reduced from 29 to 4 in 6 month period.

5/99-7/2000 Quality Engineer/Manufacturing Engineering (Contract) Bosch Braking Systems

1022 Faultless Drive

Ashland, OH

Bosch Braking Systems: Manufacturing engineering leadership and assistance with improvement of the hub and rotor machining lines. Adjust machine settings for best practices and reduction of cost. $50,000/month reduction in scrap.

2/96-2/99 Supplier Quality Engineer (Contract)

General Electric Transportation Systems

Erie, PA

Responsible for all aspects of supplier quality issues and assistance for production schedule. In one application alone saved $67,000 and solved quality issue for parts used in transit cars. Processed over 100 different parts from 4 different suppliers in 60 days to help launch new locomotive product for GE, without any delays.

11/4/85-3/28/94 Q.C. Engineer, Buyer, Production Control Specialist

New United Motor Manufacturing Inc. (TOYOTA-GM)

Fremont, CA

Responsible for all supplier parts for interior of TOYOTA Corolla, Geo Prizm, and TOYOTA Truck, for quality, delivery, and cost. Solved over 350 part problems, before launch of new model in 1988. Coordinated build out at end of model year for Production Control in 1992 for stamping shop with no excess or obsolescence. Saved over $45,000.00 per yr. for one paint shop application

EDUCATION

King's College, University of London, England

M.S. Mechanical Engineering-1980

California State University, Hayward

B.S. Mechanical Engineering-1978

University of California, Berkeley

Business Law, Economics, History, Languages

Merrit Junior College

Oakland, CA

Seminars

Statistics, Problem Solving, Negotiation, Computer Workshops, TOYOTA Production System

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