FRANCIS G. “FRANK” CALDERONE

**** *** ***** **** **********, Louisiana 71303 318-***-**** vujahg@r.postjobfree.com

DIRECTOR OF QUALITY/ DIRECTOR OF OPERATIONS

Quality Management / Multi-plant Operations / Quality Strategy-Policy / Corporate Leadership-Culture of Excellence / Defect Reduction / Reduction in Cost of Quality / Value Stream Development / Continuous Improvement / 8D Problem Solving/ Risk Management Processes / Regulatory Compliance / ISO 9001 / TS16949 / ASME / LEAN / SPC/ 8D / FMEA / Key Quality Metrics / PPAP / APQP / CAR / Six Sigma / Inspection Processes / Int. & Ext. Audits /

Plant Operations Management / Plant Start-Ups / Budgets & P&L / Cost Control / Key Operating Metrics / Capital Eq. Justification / ROI / ERP / MRP / New Product Development / Foreign Supplier Mgt / Manufacturing Engineering

Combining quality control expertise with broad manufacturing operations and sales experience, I design, implement, manage, maintain and continuously improve qualitative strategies and systems that achieve financial, business and operational objectives. I hold a demonstrated record of hands-on methods for containing costs, satisfying operations requirements, customer/regulatory requirements and product/quality standards while increasing customer satisfaction, improving profitability and minimizing risk.

Creating, implementing, improving QM systems ISO 9001/14000/TS16949, ASME I, III & VIII multi plant quality strategy and tactics, quality processes, QA procedures, document control, process mapping

P&L Responsibility, Break-Even Analysis, Capital Expenditure Justification, Internal/External Audit

Directing all aspects of production operations scheduling and on time delivery, product development concept through production, process/design review, validation and verification processes, regulatory/legislative compliance

Controlling key metrics of performance, improving product, cost containment, audit, charting, MS office, Cpk improvement, Measurement Analysis, Calibration Sys, Warranty Reduction, QA software.

Driving/Implementing continuous improvement, corrective/preventive action, internal audit, SPC, Pareto, fishbone, LEAN, interacting with customers for improvements, PAR, CAR

Leading, training, and mentoring operations and quality managers in management skills, a team leader, hands-on problem solving, team approaches, presentations to customers

Interface with supplier/subcontractors insuring performance requirements, product quality yield, delivery, cost, with evaluation audits, quality methodologies, SCAR/SPAR, Scorecard

Performance driven management professional capable of rapidly synthesizing information and making timely, high-quality decisions. I am a dynamic, participatory leader of managers with excellent communication skills, problem solving and team building talents. I hold a BS in Industrial Management from the University of Akron, possess professional presentation skills, am a Certified Trainer of internal auditors, multiple manufacturing and quality control disciplines and promote a Culture of Excellence.

SELECTED ACCOMPLISHMENTS

Start-up of Manufacturing Facility. Buckhorn Inc. purchased bankrupt organization. Designed and implemented new products, volume manufacturing processes and quality control schemes. Identified, purchased and integrated 27 major plant assets. Increased product volume, reduced failures, managed suppliers. Increased profitability 18%.

Realigned Production Tolerances. Manufacturing plant needed to restore useable tolerances for machined parts. Created team of engineers, suppliers and inspectors to analyze specifications. Developed standards for waivered and critical tolerances, defined critical dimensions, improving manufacturing results, improved inspection methods. Reduced failures to below 1%, saving $4.5M/year.

Implemented Statistical Process Controls. Up to 30% of internally machined components were out-of-tolerance. Evaluated production operations, identifying problem areas. Developed strategy to improve quality and overcome manufacturing delays. Introduced, trained, implemented and maintained SPC, eliminating fit problems. Implemented SPC for Incoming Quality Control (IQC) sub-lot acceptance.

Initiated Supplier Certification Program. Manufacturer never assessed and approved suppliers to a common standard. Designed supplier on-site quality system, audit and measurement scorecard system, implemented supplier PPAP, developed supplier certification requirements. Measured quality, delivery and pricing factors, dramatically improving supplier performance. Reduced parts failures over 95%, growing profits. Eliminated Manufacturer’s receiving inspection requirement.

Implemented ERP System. Manufacturing organization needed to improve its production control scheduling and supply chain processes. Successfully implemented system that improved on-time delivery from 78% to 99%.

Instituted ISO9001 Quality Management System. Quality Systems Implementers tasked to implement LEAN processes for major manufacturing firm. Assessed production capabilities. Conducted feedback session with company executives. Developed QMS as a start-up company with few procedures in place at outset. Stabilized company systems, attaining Registration Accreditation Board certification.

Designed Creative Continuous Improvement Program. Ingersoll Rand manufacturing plant employees did not participate in vital program. Studied local culture and economy. Developed strategy to get worker buy-in, creating unique incentives. Implemented highly successful program, improving market share, margins and morale.

CAREER SUMMARY

Manager of Quality, Dresser Inc., 2010 to present. Lead team of quality managers, quality engineers, supplier quality engineers, inspection supervisors, and inspection personnel. Included regulatory affairs and nuclear and commercial products. Reduced warranty claims by $400k per quarter.

Quality Director/General Manager, Quality Systems Implementers, Inc., 2007 to Present. Re-defined the clients role for Quality and Operations Management, trained and mentored Managers & Directors. Direct all deliverables, including negotiation, evaluation, strategic and tactical planning for leading manufacturing consultant firm. Worked with corporate executives and workforce to ensure, improve, and implement quality systems, production and operational efficiencies.

Director – Quality Assurance Group, Quality Systems Implementers, 1999 to 2007. Led highly-skilled team of six consultants, supporting quality system improvements for major manufacturing companies, including aerospace, military complex and precision tool and die producers. Supported client sales and marketing teams. Guided local quality managers. Held various roles including Director of Quality Assurance and Quality Manager for leading companies.

Director – Manufacturing Operations Group, Quality Systems Implementers, 1994 to 2001. Managed tiger team, working with client presidents, operations/finance managers and business administrators to achieve effective collaboration between manufacturing operations and corporate objectives. Guided local manufacturing managers. Mentored new consultants. Held various roles including Manager of Manufacturing and Director of Production Operations for major companies.

Earlier: Director of Quality Assurance, Hobart Brothers Company. Director of Quality & Manager of Manufacturing, Superior Valve Company. Manager of Manufacturing and Operations, Buckhorn Incorporated. Manager of Manufacturing Engineering, Lee Norse Company. Staff Manufacturing Engineer, Rockwell International. Manufacturing Engineer, Bucyrus-Erie.

Personal: I enjoy community service with Hospice and Special Olympics, weight lifting, biking, golf, photography, cooking and trap shooting.

Supplemental Resume Detail Sheet

(Attached/Available))

FRANCIS G. “FRANK” CALDERONE

5243 Rue Notre Dame Alexandria, Louisiana 71303 318-***-**** vujahg@r.postjobfree.com

Dear:

I increase profitability by initiating or improving quality processes … reduce costs by managing the full spectrum of quality assurance and operations options across multiple product platforms and minimize risk by implementing key quality and operational strategies, principles and practices. I have done this for others as a full time executive… and consultant.

My skills encompass strategic planning, ERP/MRP, on-time delivery, P&L, Capital Equipment Justification, establishing Corporate Leadership-Culture of Excellence, Defect Reduction, Reduction In Cost Of Quality, Value Stream Development- LEAN processes, Continuous Improvement, Problem Solving Disciplines, Risk Management Processes, including ISO system implementations, TQM, LEAN and Six Sigma quality controls corporate-wide, multi-site.

I combine quality control expertise with broad manufacturing operations management experience and sales experience to improve margins and increase customer satisfaction.

Having held numerous titles ranging from Corporate-wide Director of Quality Assurance, Director of Manufacturing Operations at a plant level and Staff Engineer, I develop and manage strong collaborative relationships between QA and manufacturing operations.

For example, I implemented process controls for a operations where one-third of the internally manufactured parts were out-of-tolerance. This involved commissioning and leading a cross-functional team, evaluating production operations, identifying problem areas and developing a strategy to improve quality and overcome manufacturing delays, and eliminating all problem issues.

Throughout my career, others have recognized my ability to synthesize complex, diverse information, and make timely, profitable decisions. I am a dynamic, participatory leader with excellent problem solving and team building talents. I work equally well with customers and suppliers. I am a Certified Trainer in multiple manufacturing and quality control disciplines and use this skill to develop personnel.

My broad and diverse manufacturing, engineering and quality assurance background makes me uniquely qualified to add significant value to your operations.

With a BS in Industrial Management from the University of Akron, I also am experienced in business and financial functions. I would enjoy sharing ideas with you about improving your company’s bottom line.

Sincerely,

Frank Calderone

Frank Calderone

Supplemental Resume Detail Sheet

Table of experiences and chronological history of employment

KNOWLEDGE & EXPERIENCE AREAS

Internal Audits (65+) Internal Auditor Trainer Corporate Quality Programs Sales &Marketing

ISO 9001 Certifications Problem Solving Trainer Local Quality Responsibility Facilities Maintenance

AS 9100 Certifications Quality Management Trainer Production Management Human Resource Dev

QS 9000 Certifications Continuous Improvement Organizational Development Training Programs

TS 16949 Certifications Statistical Process Control Leading Process Dev. Teams Management Review

Guide 25 Certifications

Calibration Providers Employee Training ISO, AS,

QS, TS, Guide 25 Based Systems Business Management - President Corrective/Preventive

Action Programs

Plexus Certified Trainer Leading QMS Implementations P&L Responsibility Human Relations

PROCESS EXPERIENCE AND PRODUCT AREAS

Tool & Die Metal Acid Cleaning Plastic & Metal Extrusion Refrigeration Valves

Can Tooling Aerospace Components Parts Robotic & NC Machining Compressed Gas Valves

Metal Fabrication & Cutting Aerospace Landing Gear Robotic Assembly Stamped Metal Shelving

Metal Forming, Rolling Gear Cutting & Forming Painting Pallet Rack

Metal Casting (Steel, Iron Bronze, Brass, Alum, Zinc) Military & Commercial Aerospace Engine Containers Electrical Motors, Electric Ground Power (Aerospace), River Boats & Barges (Oil, Coal, Grain Transportation)

Metal Stamping Thread Cutting & Forming Wire Extrusion Nuclear Power Plants

Metal Machining Plastic Injection Molding Design Processes Surface Mine Equipment

Metal Roll Forming Wire EDM Processes Construction Administration Deep Mining Equipment

Metal Welding Automated Assembly Calibration Welding Machines

Building Erection Manual assembly Laboratory Testing Water & Gas Meters

Field Erection Industrial Engineering Component Testing Automotive Part Assembly

EXPERIENCE PROFILE

Dresser, Inc. Div. of General Electric Company 2010 to 2012

A manufacturer of ASME I, III & VIII high pressure safety relief valves for nuclear and commercial applications

Manager of Quality

Quality Leader for Quality Control and Quality Assurance valve manufacturing reporting to the site Operations Manager

Maintained 24 quality system certifications, including ASME, NRC, China, PED, API, ISO, standards

Reduced warranty costs by 50% (250k), improved first pass yield from 40% to 85%, reduced inspection cycle time to 24hrs.

Developed quality measures for manufacturing processes and facilitated cost reductions with leadership team.

Developed plant wide internal auditing program, trained 24 int. auditors from all departments within the plant.

Audited and certified/approved suppliers for RFQ and permission to ship components for valves.

Revised and Maintained all quality system manuals and documentation

Direct Reports: Supervisor QA, Supervisor QC, 1 Insp. Sup., 2 Quality Eng., 2 Supplier Quality Eng, 20 inspectors

Quality Systems Implementers, Inc. (Troy, OH) 1994 to 2010

A consulting and training organization for Quality Management System Certification to ISO based System Standards including management and workforce development.

Quality Director/General Manager

Principal operating officer accountable for all aspects of marketing, sales, consulting operations and administration. Manages 5 associate consultants.

Re-defined the clients role for Quality and Operations Management, trained and mentored Managers & Directors

Project management for over 60 clients leading to system registrations to ISO, AS, QS, and TS based Quality Standards.

Trained over 400 internal auditors in Plexus Internal Auditor Training System

Led training sessions and established curricula for 5,000 managers and employees in Quality Management Skills, Quality Action Teams (problem solving) and Quality Awareness (continuous improvement) processes.

Conducted Gap-assessment and management and employee Skills Assessments to ID quality system and training needs.

Hobart Brothers Company, (Troy, OH) 1992 to 1994

A manufacturer of welding machines, weld wire, electric ground power units & robotic weld systems, sales $300 million.

Corporate Director of Quality

Reported to the President with responsibilities for all quality related issues corporate wide including ISO registration, Total Quality Management and over-all improvement of manufacturing and quality processes.

Led Board of Directors and senior management in developing quality initiatives, commitment and support for continuous improvement programs, supplier audit and certification, customer satisfaction measures and ISO registration.

Assessed organizational quality culture identifying strengths and areas requiring improvement.

Created an organizational structure (quality councils) for improvement that became Management Review Committees under the ISO quality management system.

Superior Valve Company, (Washington Pennsylvania) 1984 to 1992

Manufacturer of compressed gas cylinder and refrigeration valves and related components, 300+ employees, sales $50 million.

Manager of Quality Assurance – Superior Valve (1986 – 1992)

This was the top Quality operating position reporting to the VP and General Manager (plant) and VP of Technology (corporate)

Directed 18 full time quality department personnel

Led implementation of continuous improvement program. Results included: 30% reductions in Costs of Quality; reductions from 7% to 1.5% for rejections at incoming goods inspection; reductions of 11% to 1.5% at final inspection & test; 0% product liability and customer returns in the first 2 years of the program and later year.

Reduced number of out–of–tolerance machined components and overall part tolerance variability.

Reduced machined scrap and rework costs to improve fit and function at final assembly.

Developed supplier audit and certification program using ISO standard for suppliers in process of ISO registration.

Implemented ISO 9000 QMS achieved Ford Motor Co. Q1 certification prior to ISO registration.

Manager of Manufacturing - Superior Valve (1984 to 1986)

Responsible for directing manufacturing production personnel, on time shipments and achievement of favorable Profit & Loss activities. Directed ancillary support activities as well including: industrial engineering, business planning, plant engineering, tool engineering, calibration, safety and maintenance.

Coordinated implementation of ERP/MRPII materials and production control computer system improving deliveries to customers from 78% to 98% and receiving a Class a MRPII rating.

Consistently met product goals and on time shipping levels.

Buckhorn Incorporated (Steubenville, OH) 1983 to 1984

Manufacturer of plastic injection molded parts & stamped, roll-formed and painted metal shelving and pallet rack, sales $54 million.

Manager of Manufacturing

Reported to VP Operations and was responsible for general management activities at the 200+ employee manufacturing facility producing metal shelving, and pallet rack for commercial and consumer markets.

Improved process technology by automating three continuously operating, flexible high volume, production lines increasing product output and quality.

Led the installation of an automated paint line with robotic paint applications.

Ingersoll Rand Corporation, Lee-Norse Division (Pittsburgh, PA) 1978 to 1984

International manufacturer of capital goods equipment, underground mining machinery, sales 1.4 billion

Manager of Manufacturing Engineering (Beckley, WV, 1980-1984)

Reported to Beckley Plant General Manager, with responsibilities for Industrial Engineering Department activities of 5 industrial engineers and Maintenance Department 7 mechanics including: documented process control, continuous improvement, cost reduction program, new product development, fixture design, tool design and preventive maintenance.

Successfully implemented an Industrial Engineering function and reduced labor costs by 25%.

Successfully implemented a Preventive Maintenance program.

Manufacturing Engineer (Pittsburgh, PA, 1978-1980)

Reported to VP Manufacturing, with responsibilities for project management of operating plants in Beckley, WV & Charleroi, PA including: continuous process improvement, capital equipment selection and justification, facilities expansion, new product development, fixture design and tool design.

Reduced assembly and weld hours by 60% with fixturing for position welding of multiple ton weldments.

Developed assembly and weld fixtures for mining machinery components for 40% reduction in cost.

Led team in developing testing facility for finished mining equipment prior to shipping to customers.

EARLIER CAREER

Rockwell International, Municipal & Utility Div.: Multi-plant Manufacturing Engineer, water and gas meters, (1,500 employees)

Pittsburgh. Pa. (1977-78)

Bucyrus-Erie Company, Manufacturing Engineer: Surface Mining Machinery (Elect. Shovels, Drag Lines & Blast Drills) (3,000 employees) Milwaukee, WI, (1975-77)

EDUCATION AND TRAINING OVERVIEW

Plexus Training Systems, Certified Trainer all programs including ISO, QS, TS, AS quality management systems

Organizational Dynamics Inc, Certified Trainer/Facilitator, Quality Management Skills, Quality Action Teams, Quality Awareness

Interact Performance Systems Inc., Certified Trainer (All courses), management development, workforce development

University of Wisconsin, MBA (Program credits)

University of Akron, B.S. Industrial Management

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