Quality Assurance Six Sigma
Resume:
TODD THORNBROUGH
Dover, FL 33527
****************@*****.***
480-***-**** (Cell)
813-***-**** (Home)
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Lean Six Sigma Program Management Leader
Manufacturing Defense Aerospace
Innovative, results-driven quality professional and Six Sigma Black Belt with more than 13 years of experience delivering operational excellence, improving production performance, and reducing expenses by millions of dollars. Possess strong record of continuous improvement leadership through Lean Manufacturing technology, Statistical Process Control (SPC), and data acquisition / analysis using Minitab® software. Highly experienced quality assurance manager, engineer, and ISO auditor.
Six Sigma Black Belt (SSBB)
Lean Manufacturing Sensei
Quality Assurance Management
Data Warehouse Management
Six Sigma Green Belt Trainer
ISO 9001:2008 QMS Systems
Productivity Improvements
AS 9100 New Product Qualification
Articulate Communicator/Team Leader
SAP Data Analysis
New Product Qualifications
J-STD-001D Certified Instructor
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Professional Experience
CITIGROUP, Tampa, FL February 2011– Present
Vice President, Process Improvement, Citi Shared Services
Responsible for the Process Improvement activities for Citicorp (a division of Citigroup) for the Financial Reporting Organization.
Developed Lean manufacturing training materials with examples.
Global Training Lead of Lean Six Sigma process for Citi. Developed Lean materials for global implementation throughout Financial Reporting Organization (FRO) and Citi Shared Services (CSS). Provided train the trainer and program oversight for more than 2,000 Citi employees. International locations including Costa Rica and Manila.
Provided global "Train the Trainer" support for staff on lean concepts and training initiatives.
Developed monthly training metrics for senior management staff for all sites.
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SMART MODULAR TECHNOLOGIES, Phoenix, AZ May 2010– November 2010
Senior Quality Assurance Engineer, Defense Data Storage Systems
Reporting to the Director of World Wide Quality, manage incoming inspection of components, in-process PCBA assembly inspection, final test and packaging for a $150M/year business. Provide support for operations, product design engineering, and customer support engineering including data analysis.
Attained product life cycle procedures and material shelf life process improvements that led to completion of third party ISO recertification with no major non-conformances by conducting ISO 9001:2008 audits of manufacturing, engineering, and quality management systems (QMS).
Reduced assembly related errors 31% by suppliers and contract manufacturers; cut work in progress materials by $50K through managing Material Review Board (MRB) for discrepant incoming and in-process materials.
Decreased hardware assembly discrepant materials 90% and facilitated continuous improvement projects by creating and reporting production quality metrics including supplier and internal processing performance on an intranet website for management and engineering review.
Reduced overdue Failure Analysis and Reporting (FAR) 75% by monitoring latency and conducting FAR of returned materials from customer and field service engineers.
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L-3 COMMUNICATIONS – ELECTRO-OPTICAL SYSTEMS, formerly Northrop Grumman - EOS, Tempe, AZ 2001–2009
Six Sigma Black Belt
Reporting to the Engineering Leader with direct interface to the Corporate Division President and Vice President of Continuous Improvement, managed continuous improvement projects from $100K–$1M supporting $300M manufacturing operations and key stake holders including engineering, manufacturing, quality, and management.
Led four individual Kaizen manufacturing projects to improve process efficiency resulting in annual savings of over $270,000 by reducing component and sub-assembly scrap.
Saved over $1.3M through assisting 8 Lean Six Sigma Green Belt teams to complete their projects.
Realized project savings of $610K annually by developing a complex query–capable data warehouse using Minitab that generated more than 800 control charts to facilitate Statistical Process Control, yield, Pareto, and scrap improvement activity resulting in data driven control systems support 2,500 critical processes.
Developed curriculum materials and successfully trained and mentored all levels from production leads to executive staff as lead instructor for EOS Division Six Sigma Black Belt training program.
Created Lean Manufacturing present/future state process maps identifying and prioritizing areas of improvement with over 50 candidate Lean Six Sigma Green/Black Belt projects.
Senior Quality Assurance Engineer
Led DD250 shipment auditing, product qualifications including IPT and new product qualifications to Mil-STD 810F. Managed and reported all product quality failure data for the quality organization. As Principle Quality Assurance Engineer for Infra Red (IR) Systems, directed all product testing and inspection, Goodrich Aerospace customer communications and site visits, and facilitated classified presentations.
Qualified new AS9100 compliant product for United States Air Force.
Ensured division was in compliance with customer contractual requirements by creating all Electro Static Discharge (ESD) training materials and conducting facility-wide annual training (ESD 20.20).
Conducted on-site supplier audits of final and in-process product components providing approval and supplier improvement requirements.
Conducted certified J-STD-001C/D training and tested operators on training requirements resulting in contract compliance to Class III soldering standards.
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NCS PEARSON, Phoenix, AZ 1999–2001
Quality Assurance Program Manager, Government Contractor for Year 2000 U.S. Census data acquisition
Managed quality assurance program for $700M Army University Access Online (AUAO) proposal. Developed detailed quality assurance program criteria and process requirements for soldier-student Graphical User Interface (GUI) with software development team. Proposal was 2nd of 16 submitted on cost, 1st on technical content.
Wrote program management section of the AUAO proposal, including all scheduled deliveries.
Developed all statement-of-work (SOW) requirements for quality assurance subcontractors.
Quality Assurance Manager
Directed inspection activities for a team of 25 staff members during processing of census forms. Developed inspection database and protocols that automated reporting functions at 3 processing facilities throughout the United States with the Bureau of Census in Washington, DC.
Conducted interface with on-site customer regarding processing issues and corrective action; conducted quality assurance overview for all new employee orientations.
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SONORA SOUTHWEST, Tucson, AZ 1998–1999
Quality Assurance Manager, Injection Molder of high precision plastic parts for RainBird® in-ground sprinklers
Reporting directly to the Plant Manager and Vice President for Quality Assurance, developed a start up manufacturing facility including staffing of inspection personnel, quality process procedures, and developing key metrics for process monitoring.
Supervised inspection activities of more than 28 employees including doubling staffing from 12 inspectors to 24, and from 2 quality engineers to 4. Automated metrics data collection and analysis using Minitab statistical software.
Led organization through 1st successful audit (ISO 2001:1994) enabling division to qualify for material acceptance by other divisions.
Served as lead auditor of international manufacturing and assembly locations.
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Education & Certifications
Master of Science–Information Management. (In process, graduation expected May 2013). Arizona State University, Tempe AZ.
Major courses: Business Intelligence, Network Security, Database Management
Bachelor of Science– Business Management. Purdue University, West Lafayette, IN
American Society for Quality, Information Systems Audit and Control Association, Arizona State University (currently enrolled)
Six Sigma Black Belt, American Society for Quality.
Certified Quality Auditor, American Society for Quality.
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