Quality Manager

STEVE LUND PHD

*** ****** ***., *********, ** *7205 ● 615-***-**** ● *********@*********.***

MANAGER / ENGINEER

Process Improvements / Lean Six Sigma / Engineering / Kaizen / Supplier Audits / Cost Control / ISO9001 & ISO13485 / AS 9100 / Supplier Management / D & PFMEA / Training / SPC / Gauge R & R / 5S / Value Stream Mapping / 8D / Process Control / Value Engineering / Root Cause Analysis/IPC 610

Directed quality management programs for durable goods producers, including aerospace, electronics, appliance, equipment and furniture manufacturers. Created innovative production solutions to reduce defect/scrap rates while improving throughput and efficiency. Revised product designs to correct flaws, improving MTBF. Developed process improvements to control costs and enhance reliability. Collaborated with suppliers to maximize quality of incoming raw materials and components. Managed budgets to $390K and staff to 15.

• Implemented innovative training for production operators at Hayward, cutting defect rates 54%.

• Introduced mobile inspection process, cutting approval time for batch runs from hours to minutes.

• Directed 5S process improvements at Globe, cutting scrap 25% and reducing downtime to save $250K.

• Revamped design and production at Globe supplier, salvaging 100,000 defective chairs and saving $1.8M.

Key Skills: Designing and implementing low-cost process enhancements to improve productivity and quality. Devising simple solutions to complex production challenges. Applying knowledge of ergonomics and kinesiology to address design and production problems.

BSME, Tennessee State University. Lean Six Sigma Green Belt, TBM.

SELECTED ACCOMPLISHMENTS

Implemented innovative training for production operators at Hayward, cutting defect rates 54%. Firm relied on spot checks by QA inspectors to catch defects coming out of press department. Identified opportunity for press operators to conduct their own continuous QC monitoring. Designed and conducted blueprint reading and test/measurement equipment training, empowering operators to identify and correct defects. Freed QA team to monitor major trouble spots. Cut defects reaching assembly stage by half and reduced scrap 33%.

Introduced mobile inspection process, cutting approval time for batch runs from hours to minutes. First-piece inspection for batch run approvals at Hayward was inefficient, centralized process. Designed and implemented mobile stations with blueprints and measurement gauges. Enabled inspectors to rapidly review test runs on fabrication floor with near-zero downtime for press operators. Identified scrap/defects earlier in production cycle, dramatically cutting waste.

Directed 5S process improvements at Globe, cutting scrap 25% and reducing downtime to save $250K. Laminating process for producing tabletops was prone to high scrap rate and excessive downtime. Traced problem to film wrinkling. Revamped laminating machine procedures and increased frequency of preventive maintenance. Cut laminating machine downtime to near zero. Produced substantial year-over-year savings.

Revamped design and production at Globe supplier, salvaging 100,000 defective chairs and saving $1.8M. Chairs from offshore vendor consistently failed endurance tests. Conducted onsite plant audit, discovering flaws in welding process. Redesigned component most prone to failure. Trained plant management on new procedure for improved welding strength/reliability. Implemented both upgrades, cutting defect rate to near-zero. Retrofit all WIP and finished goods.

Upgraded quality procedures/documentation at First Source, securing ISO9000 certification for eight facilities. Firm sought coveted ISO certification. Researched requirements, drafted quality manual and codified upper-level procedures. Trained management on developing process standards and documentation. Established document repository on company-wide intranet. Built internal ISO audit team. Won certification for seven plants and headquarters.

Corrected dangerous design/assembly flaw with Kaizen approach, totally eliminating explosion potential. Hayward pool heating venturi could be installed upside down, presenting fire/explosive risks when installed. Created cross-functional Kaizen team, including vendor, to review issue. Developed mistake-proof Poke-Yoke, offsetting mounting bracket holes to eliminate possibility of upside down orientation.

Created low-cost design revision for G.F. avoiding warranty replacement on 10,000 workstation panels. While major installation for Port Authority of NY/NJ was in progress, panels began to fail, threatening multi-million dollar warranty costs. Designed and tested new part, correcting flaw. Oversaw retrofit of all panels.

CAREER HISTORY

Quality Inspector, Hennessy Industries – Tire Changing & Balancing Equipment Mfg – Contract appointment Oct- Nov. 2011. Inspected Incoming machined parts & prepared first article inspection reports.

Quality Engineer, TS3 Technology - Electronics Mfg, 2009-2011. Developed an ISO 9001, ISO 13485 and AS 9100 compliant Quality Management system, ISO internal and Process auditing, FMEA Training and PFMEA Team Lead, Process capability analysis, In-coming inspection lead, Supplier evaluation/management, Corrective and Preventive actions, IPC 600 & 610 certified.

Quality Engineer, Moduslink Global Solutions, $1B Supply Chain Management Co. 2009. ISO auditing, data analysis, training, corrective action system management, root cause analysis, implementation of line balancing and one piece flow for first pass yield improvement

Hayward Industries, Quality Manager, pool heater manufacturer, 2001-2008. Directed all plant QA functions and budgeting. Led programs in warranty cost and scrap reduction, first-pass yield improvement and implementation of SPC and process capability studies on components, new products and processes.

Major Accomplishments:

Led or participated in 35+ Kaizen/Continuous Improvement events

Conducted 50+ supplier quality/process audits

Developed and managed a Supplier Certification/Management program.

Developed and implemented a Quality improvement team for warranty reduction

Responsible for all Quality aspects of new product introductions

Championed all company D & PFMEA teams

Developed and tested product packaging to ASTM & ISTA standards

First Source Furniture Group, Division of Haworth Inc., Quality Engineer, 1999-2001. Directed all ISO programs, product test lab and failure analysis/corrective action system. Representative on ANSI/BIFMA committees. Supervised returned goods department. Audited vendor performance as Supplier Quality Engineer.

Major Accomplishments:

Worked on site with suppliers to improve process capability and quality by utilizing capability studies, tooling changes and material changes.

• Secured ISO 9000 registration for the corporate office and all 7 plant sites and conducted semi-annual audits of all plants to ensure continued compliance.

• Implemented a design change on a sheet metal part that reduced the scrap rate for that part by 80%

Ensured company compliance to federal, state, and industry standards and codes

Conducted capability studies on new products and processes

Implemented a corrective action (CAR) program that identified quality/manufacturing/supplier

problems, their root causes, and developed and initiated corrective actions to eliminate them, utilizing quality tools such as: 8-D, 5 why, cause and effect analysis and FMEA.

Globe Furniture, Division of Haworth Inc, Quality & Test Lab Manager, 1994-1999. Directed QA Inspectors and Engineers, product/packaging test lab, return goods and warranty reporting. Designed a corrective action process for resolving supplier quality/production issues.

Major Accomplishments:

• Reduced the incidents of customer reported quality problems by 22%

• Reduced scrapped folding tabletops by 25% resulting in a savings of $250,000 per year

• Developed ISO internal audit, plant process audit, supplier audit, and plant/warehouse product quality audit programs and coordinated all auditing

• Set up the product test laboratory – including test equipment purchasing, technician training, and product-testing schedule

Earlier career: Quality Engineer & Test Lab Manager, G.F. Office Furniture and Quality Supervisor, Textron Aerostructures.

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