Quality Manager / Senior Quality Engineer / Project Manager

SHAWN M. LILE

Keego Harbor MI *****

Quality-driven and detail oriented professional with 16 years of experience in automotive quality assurance and operations. Strong qualifications and background experience in quality management and engineering, system auditing, and customer / supplier communications.

Areas of Expertise:

•Statistical data analysis and evaluation

•Training

•Microsoft program applications

•APQP / DFMEA / PFMEA / Control plans

•Project management and reporting

•Customer service and technical support

PROFESSIONAL EXPERIENCE

CHRYSLER GROUP, LLC / BARTECH, Auburn Hills, MI Jan 2005 – Dec 2010

Operations Specialist – Supplier Quality

Subject matter expert and provider of technical, data, and APQP process support for communication and decision making towards timely launch of vehicle programs, determining proactive solutions per data trend analysis, and taking reactive responses to daily issues. Provided support to Supplier Quality (Advanced, Current and Commodity) and Assembly / Manufacturing organizations.

•Coordinated on-site system assessments at high-risk supplier locations to identify systemic issues and weaknesses, determine root causes, and develop and monitor improvement plans. Served as project team lead assessor and liaison between Chrysler corporate quality management and supplier senior executives.

•Presented executive and senior management with data analysis and graphics to view, identify, and evaluate data trends. Reports completed by extracting, analyzing, and validating data from multiple web-based and mainframe systems to identify and understand systemic issue trends and root causes.

•Trained and coached Chrysler corporate and manufacturing personnel and more than 3500 production, assembly, mopar, steel, and module supplier base users on use of the Nonconformance Tracking (NCT) system, Microsoft software programs, and quality processes.

•Represented NCT system organization as Trouble Ticket Tracking System coordinator. Provided help desk support to all internal and external system users. Interfaced with customers and ITM to document system issues, questions, resolutions and closure of tickets, and maintain and update organization profiles.

COBASYS, Troy, MI Feb 2003 – Jul 2004

APQP Coordinator / Quality Assurance Engineer

Team member to initiate first quality management system for product / process design and manufacturing of Nickel Metal Hydride Batteries for transportation (hybrid-electric, electric, heavy-duty vehicle, and 42-volt) and stationary applications (telecommunications, uninterruptible power supply, and distributed generation system).

•Advised 1 corporate facility, 2 design facilities, and 3 laboratories for initial ISO/TS 16949: 2002 application and with 1 manufacturing facility for transition from existing QS-9000 system.

•Authored DPACT (Design Planning And Control Tool) and MPACT (Manufacturing Planning And Control Tool) manuals and trained CEOs, vice presidents, managers, product and process employees, and design and manufacturing engineers on application to program management, PPAP, and APQP process.

•Created and applied initial Statistical Process Control training program to assist all employees with basic statistical applications to process and product design and manufacturing operations.

•Supported application of ISO 17025 laboratory standards and TL 9000 telecommunication standards into new quality management system.

SHAWN M. LILE Page Two

HP PELZER (AUTOMOTIVE SYSTEMS), INC., Port Huron, MI Mar 2002 – Feb 2003

Quality Manager

Managed quality program for the production of automotive urethane-foam-backed inner dashes and miscellaneous acoustical components through vacuum molding, open and closed mold urethane processing, 3-D die trimming, and custom blending of polyol formulations for General Motors, Chrysler, and Honda.

•Management representative for QS-9000 and co-representative for ISO 14001 registrar audits.

•Coordinated all APQP stages for part submissions (PPAP), working with suppliers, customers, management, design and project engineers, and manufacturing employees. General Motors programs included GMX-215 / 245 (Cadillac / Corvette) and GMX-380 / 381 (Sedan / Sedan Coupe Convertible).

•Generated monthly Key Measurable reports to review customer reports, supplier issues, internal and customer PPM’s, and scrap levels, applying action items for continuous improvement.

•Supervised 11 employees, including Quality Technician, lab supervisor, lab technicians, and auditors.

GUIDE CORPORATION, Pendleton, IN Jan 2000 – Apr 2001

Corporate Quality Compliance Auditor / Management System Coordinator

Established and implemented quality auditing program for compliance to APQP documents and quality procedures for OEM and after-market injection-molded plastic lighting systems, testing of electronic circuit boards and light bulbs, and testing for government lighting regulations. Mapped management system to QS-9000 and ISO/TS 16949 requirements and assisted with ISO 9000: 2000, ISO 14001, and VDA 6.1.

•Supported Black Belt Process Resolution Engineers with six sigma project implementation and irreversible corrective actions for quality problems and institutionalizing quality improvements.

•Developed and implemented a team-oriented customer PRR training program for more than 800 employees in less than two months. Results showed a reduction in PRR's and an increase in customer satisfaction.

•Designed and executed corrective action presentation program later selected by General Motors for use by all suppliers to present data for Level 1 and Level 2 containment to corporate GM staff.

•Assisted manufacturing with reaching goals for lean manufacturing, quality improvement, and cost reduction.

Automotive Quality Engineer (1994 – 1999)

FORMAL EDUCATION

Master of Science, Iowa State University, Ames, IA, 1985-1990

Bachelor of Science, Purdue University, West Lafayette, IN, 1981-1985

PROFESSIONAL DEVELOPMENT AND AFFILIATIONS

Chrysler Recognition of Excellence, 2010

Chrysler Recognition of Excellence, Senior Vice President, 2009

Board of Directors: Harbor Village Homeowner’s Association

Implementing APQP/Product Realization – APQP, Control Plan and PPAP

Certified ISO/TS 16949 Lead Auditor, 2002

Certified ISO/TS 16949 Supplier Auditor, 2002

Certified Internal ISO 14000 Auditor, 2001

Understanding and Implementing ISO/IEC 17025

Leadership Series Certificate

Continued Education – University of Illinois, 1990-1992

Statistical Consultant – University of Illinois

Publication, Thesis, Iowa Academy of Sciences

SHAWN M. LILE ACCOMPLISHMENTS Page Three

*Project team lead assessor for Chrysler while with the Quality Assurance and Audit Team (QAAT). Coordinated supplier on-site system assessments to identify systemic issues and weaknesses, determine root causes, and develop and monitor improvement plans. Projects included Magna New Process Gear, FTE Automotive, Collins & Aikman, Linamar-Corvex, Textron, and Magna Intier Automotive.

*Lead Jeep plastic hardtop mold operations and supported assembly, paint, and final audit and testing during immediate transition to a new Chrysler supplier. Team efforts increased shipment rate from 0 to 400+ hardtops per day within 4 weeks and prevented Jeep assembly plant shutdown.

*Reviewed and modified process flow diagrams, control plans, and pFMEAs to meet immediate transition to new Jeep 2-door and 4-door plastic hardtop supplier operations that included tooling, molding, assembly, paint, and audit / testing.

*Coordinated all APQP stages for part submissions, working with suppliers, customers, design engineers, project engineers, manufacturing, technicians, and management. General Motors programs included GMX-215 / 245 (Cadillac / Corvette) and GMX-380 / 381 (Sedan / Sedan Coupe Convertible).

*Updated all process flow diagrams, control plans, and pFMEAs for compliance to actual manufacturing process of injection molded plastic lighting systems. Operations included raw materials, component molding and assembly, testing of electronic circuit boards and light bulbs, and testing for government lighting regulations.

*Developed, organized, and implemented a team-oriented customer Problem Reporting/Resolution (PR/R’s) training program for more than 800 employees in less than two months. Results showed a reduction in PR/R's and an increase in customer satisfaction.

*Provided technical leadership to educate departments, with emphasis towards upper management and engineering, on the performance of daily duties and compliance with new or existing quality systems, including QS-9000, ISO 14001, ISO 9000/TS 16949, VDA 6.1, and ISO 17025.

*Developed DPACT (Design Planning And Control Tool) and MPACT (Manufacturing Planning And Control Tool) manual and consulted all users on application to program management and APQP process (included CEOs, vice presidents, managers, supervisors, and engineers (design, process, manufacturing, and quality).

*Utilized 8-D, 7-Step, 5W2H, or 5-Why as methods for approaching corrective actions.

*Lead 3-day Kaizen event, approaching open and previously closed corrective actions, resulting in nearly 90% deletion of items obtained from previous internal audits.

*DOE project at General Motors relative to corrective actions lead to reduction of material sorts from 400% to 100%. GM decided that further review of the manufacturing process was necessary.

*DOE project with factorial design to reduce scrap levels of Ford steering column boots. Design set-up, training of personnel, and collection and analysis of data led to reduction of scrap from range levels greater than 60% to range levels between 0% and 10%, dependent upon color.

*Development of initial Statistical Process Control training to assist all employees with basic statistical applications to process and product design operations.

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