Automotive - Supplier Quality

RUSSELL L. FRAYER

** *** **. **** * Valley, Alabama 36854 * 706-***-****

*******@*******.***

SUMMARY

A Tier One - Quality Manager, Supply Chain Engineer & Quality Engineer having progressive leadership in quality and manufacturing processes. Experiences range from metal fabrication of chassis, chassis modules and air bag assemblies, the rotating fan industry and their associated components & assemblies. I have supported multiple projects for both customers and suppliers in England, Germany, Mexico and Canada, as well as throughout the USA. I am experienced in most quality standards as well as TS, and noted as an accurate, aggressive, self starter with excellent work ethics, coupled with both competitive and high energy attitudes.

EXPERIENCE

Takata Holdings 6/2006 – 9/2008

- Tier I supplier to the O.E.M market of safety related systems – i.e. Air Bags, Seat Belts, & Steering Wheels

Advance Supplier Quality Engineer Various (Program’s)

- “Metal Stamping Process Specialist” with responsibilities in developing stampings, welded assemblies, and injection molded safety components from supplier launch to SOP in multiple facilities located in the USA and Mexico.

 Assisted plant quality team personnel in customer APQP processes

 Supported multiple project launches and supplier reviews prior to awarding contracts

 Responsible for creation and maintenance of the tool tracking process (Managed up to 48 dies simultaneously)

 Reviewed and approved all Quality Documentation in preparation of Supplier PPAP’s prior to release for production assembly

 Shared approval and buy-off of all processes, gauges and documentation submitted by supplier’s facilities in Mexico

 Emphasis on metal stampings, robotic welding processes, injection molded covers, & traceability systems

Benteler Automotive 9/1998 – 2/2006

- Tier I supplier to the OEM market of Welded Chassis’s, Chassis Modules, Exhaust Components and Safety Impact Structures as an industry leader in tubing, hot stamping and hydro formed products.

Sr. Quality Engineer BMW E-70 (X5 - Program)

Part of a four-man project team responsible for the development and launch of the Front & Rear Welded Chassis’s and Bumper assemblies. Reporting to the Project Manager / Plant Business Unit Leader I was responsible for managing all quality functions related to the projects equipment buy-off and supplier readiness through PPAP for all stampings, gauges, assemblies and their processes.

 Maintained full APQP documentation and project readiness for both Chassis & Bumper projects

 Assisted in selection and development of stamping and equipment supplier’s from kick off through PPAP.

 Creation of all Quality Documentation in preparation of project PPAP’s at the plant level.

 Responsible for the creation and implementation by the Tooling Supplier, for the Traceability process.

Plant Quality Manager DCX LX Program (300C / Dodge Magnum)

Reporting to the Plant Manager and Quality Director of NAO while managing a team of six quality engineers & sixteen support specialists! Responsibilities included all quality systems and functions related to the finished assembly and supply chain for both the “Front & Rear Chassis Modules”. Lead the initial quality system from conception through the first year for a plant of 350 employees, from proto type to the initial launch phase for a JIS (Just in Sequence) Facility.

 Established training courses for all new recruits — speeding profitability and stability for quality & production

 Quality & Manufacturing Mgr’s as a team oversaw nearly 300 Engineering Changes in the first 10 months

 Responsible for all reporting BOS systems to both DCX and Benteler Corporate

 Managed all Supplier related Issues for over 50 suppliers and 170 components.

 Implemented an automated material reject inventory system, allowing full traceability of all associated MRB rejects

PROFESSIONAL EXPERIENCE – continued:

Supplier Quality Engineer DCX CS Program (Pacifica)

Reporting to the VP of Chassis systems while implementing and managing a team which supported all internal inspection and containment activities that secured all defects prior to customer receipt. Responsible for sourcing all Supplier 3PVA activities for the facility along with their costs associated with downtime due to all incoming defects.

 Implemented all third party containment processes within the assembly plant to eliminate complaints / PPM.

 Established and maintained all costs related to supplier downtime for accounting / logistics.

 Supported customer quality concerns with the launch processes through team trouble shooting techniques – 7S’s

Quality Engineer Ford Jaguar Aston Martin (D/EW98, M-205, X200)

Reporting to the Business Unit Leader & Quality Manager while sustaining all floor quality functions, customer liaison interactions and supplier issues, from development through PPAP

 Customer support liaison for 4 years for Ford, Jaguar, Aston Martin and Tower Automotive

 Part of a four man team responsible for the M-205 and D/EW 2003 Front Cross member programs

 Implemented all weld tracking & validation processes and procedures throughout NAO - 1999 forward.

 Reduced downtime due to weld repairs to an overall average of 1.5% / unit.

 Developed containment and disposition policies for plant projects reducing inventory and scrap.

 Awarded two “Continuous Improvement Awards”

 Implementation of “UPAS” Standards throughout NAO

Amerimax Inc. (Div. of Amax Corp.) 7/1994 – 8/1998

- Leader in RV & Building Home Products for the “Manufactured Housing Industry”.

Quality Supervisor / Mfg Engineer

Reporting to the Plant Manager & VP of Operations, while managing a team of three employees for the quality department

 Responsible for developing and tracking product testing procedures for laminated products

 Assisted vendor of SMC’s in developing grading scales for defects relative to the industry

 Oversaw customer product quality

 In charge of all equipment maintenance schedules and purchase of new or replacement components

EDUCATION / PROFFESSIONAL TRAINING

 Southwestern Michigan College - Associates Degree in Engineering and Applied Science

 Southwestern Michigan College - Associates Degree in General Studies

Certifications - ASME Welder - Section IX Qualification,

Journeyman Tool & Die Maker, Kepner Tregoe (Problem Solving & Decision Making)

2001 – Member of the American Society of Quality

Six Sigma Certification - Green Belt

AT Kearney – K1, K2, K3 Processes

ISO / TS 16949-2002

SKILL SETS

* Team based work systems * Six Sigma Greenbelt * Project Management

* Trained ISO / TS 16949-2002 * GD&T * Visual factory and Kanban / Pull Systems

* Manufacturing cell & layout design * Lean Manufacturing Concepts * Supplier development

* Strategic Planning * OEM / Supplier PPAP * 8D, 7S, 5 Why’s

* Third party management * New product start ups * Capability Studies

* Gauge Design / R&R * Stampings (CR / HSLA) * Weld Testing & Inspection

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