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Quality Assurance Manager

Location:
Newton, North Carolina, 28658, United States
Posted:
March 08, 2011

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LEIVA URMAN

**** ******* ****** *****

Newton, NC 28658

E-mail: ur5yvw@r.postjobfree.com Cell: 828-***-****

SUMMARY

Highly experienced Quality Assurance Manager (CQE) and Continuous Improvement leader (ASQ-certified Six Sigma Black Belt) with strong background in operations, organizational development and industrial engineering. Expertise in statistical methods, SPC, plans of control, DOE and data analysis. Experience managing international suppliers and global customers in a broad range of industries and manufacturing processes. Fluent in Spanish and English.

EXPERIENCE SUMMARY

SAFT AMERICA, INC. – Valdese, NC 2007 – 2010

Design, development and manufacture of high performance primary lithium and lithium ion rechargeable batteries for industrial and defense applications.

Quality Assurance Manager

As management representative, responsible for compliance to the ISO001:2008 quality management system. This included managing traditional quality assurance functions such as quality engineering, incoming inspection, non-conforming material dispositions, CAPA program, customer complaints and internal auditing system. Host customer and third party audits. Assured QMS supported FDA requirements for customers with medical applications. Manage two salary and four hourly associates. On temporary basis, led lean activities such as point Kaizen (line organization events), 5S and SMED.

Revised incoming inspection skip lot plan, increased frequency of supplier audits, closer monitoring of high

volume and repeat offender suppliers led to a reduction by 30% in frequency of non-conforming materials.

Improved Incoming Inspection efficiency through reduction of inspected lots by 10 percentage points.

Led Customer Satisfaction PDCA team focused on reducing response time to the customer. Reduction was 12%.

Expanded use of SPC software to capture data from added equipment and new processes.

Redesigned the supplier audit plan to allow for either on-site audits or self audit by supplier.

Certified Quality Management System to ISO9001:2008 standards with zero deficiencies.

Upgraded Quality Manual to meet FAA requirements.

Reduced cost of destructive testing by $47,000 per year while maintaining process capability. Used SPC software

to identify processes with high Cpk and prioritized efforts based on dollar impact.

Reduced calibration costs by $18,000 per year by building capability to perform calibration in-house, increased

verification processes before performing calibration and reviewed usage prior to routine calibrations.

Redesigned 5S program by making the program team based by area and providing incentives for exceeding goals.

Completed SMED events and refined those already in place.

Established priorities for blitz Kaizen events and simplified the savings tracking methods.

Implemented electronic web based system to manage and maintain Material Safety Data Sheets.

WEBSTER INDUSTRIES, INC. – Montgomery, AL 2000- 2007

Manufacturer of plastic trash bags, food contact products and packaging solutions for our private label and commercial/industrial business partners and our own value brands.

Plant Quality Control Manager and Reprocessing Manager – 2006 – 2007

Responsible for product quality and product safety. Also managed Reprocessing Department, which compounded 30 million pounds of internal and purchased scrap annually into raw material for reuse. Supervised four salary direct reports and 43 hourly employees.

Reorganized Quality Department to increase focus on process monitoring and eliminated two positions.

Led cross functional team to reduce leaking defects on food storage bags by 11%.

Operations Manager, Liners and Reclaim – 2004 - 2006

Managed manufacturing of plastic can liners and reprocessing of internal and purchased scrap. Nine salary direct reports and 240 hourly employees.

Reduced cost of blended material via introduction of lower cost substitute without adverse effects in quality and

processing. Expect annual cost savings in excess of $250,000 by the end of 2005.

Corporate Quality Manager – 2000 - 2004

Position was vacant for almost 900 days.

Five salary direct reports and 17 Quality Assurance Inspectors.

Six Sigma certification project resulted in savings over $300,000 by reduction of scrap and plastic pellet defects.

Reduced finished product holds by 20% by implementing procedures focused on prevention of quality defects.

Initiated use of acceptance sampling plans for purchased products reducing converting problems

Applied Six Sigma methodology to implement Good Manufacturing Practices program. Obtained rating of

“Excellent” in the first independent audit.

FORT JAMES CORPORATION 1973-2000

Note: Georgia Pacific acquired Fort James Corporation in 2000

Manager, National Quality Assurance - Dixie Products – Easton, PA 1987-2000

Managed the application of standard quality assurance procedures and methods at nine plants with sales of $800 million. Managed staff of four.

Directed and managed compliance with GMP HACCP for all facilities. Including IMS and Kosher certifications.

Implemented SPC in a testing laboratory, improving test results and equipment reliability.

Developed a quality manual for Cutlery that is ISO9000 compliant.

Developed and implemented an approach for certification of newly installed equipment, enabling identification of

problems in the early stages of production.

Used Design of Experiments (DOE) techniques to improve processing conditions leading to significant reduction

in customer dissatisfaction.

Led implementation of centerlining technique on a 96-cavity mold reducing cycle time by 20% for the injection molding line.

Coordinator, Organizational Development - Naheola Mill Towel and Tissue Division – Pennington, AL 1986-1987

Led programs that increased employee participation in process improvement and quality of work life.

Facilitated team building and task forces.

Co-led implementation of a high performance work system in the Accounting Department.

Developed and conducted the first SPC training program for Bleach Plant Operators focused on individuals and

moving range charts.

Facilitator for the Accounting and Finance Departments of the Towel and Tissue Division

Quality Engineer - Naheola Mill 1982-1986

Focused on data analysis, supervised eight hourly inspectors

Responsible for test equipment in the four testing laboratories

Member of product development and commercialization team commercial paper towels

Productivity Engineer - Naheola Mill 1980-1982

Developed and maintained production standards for all Mill operations.

Led implementation of $750,000 reduction in packaging and shipping costs through the redesign of corrugated containers.

Member of three-man task force that developed and implemented a quality control program, reducing costs $30,000 per year.

EDUCATION

B.S. Engineering Operations, North Carolina State University

B.A. Liberal Arts, North Carolina State University

PROFESSIONAL DEVELOPMENT

TQM, Statistical Process Control, Design of Experiments,

Facilitator Skills, Consulting Skills, ISO9000, Injection Molding

ADDITIONAL INFORMATION

Certified Six Sigma Black Belt by ASQ

Certified Quality Engineer by ASQ

Bilingual in Spanish and English



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