Project Manager Quality
Resume:
Doug Lewandowski
Sylvania, OH 43560
419-***-**** (h) 419-***-**** (c)
wmr99j@r.postjobfree.com
Skill Summary
• Quality systems development for ISO 9001/TS16949 auditing and audit preparation
• Automotive components manufacturing (engine components, valve train, plastic interior/exterior trim)
• Refining operations experience in OSHA inspections, contractor supervision and management
• Manufacturing process expertise (Steel manufacturing, aluminum die casting, cast iron, steel stamping, forming, grinding, welding, spinning, deep drawing and metal finishing)
• Statistical expertise for Statistical Process Control, Experimental Design, and ANOVA methods
• Supply Chain/Logistics experience
• Direct and indirect supervision in union and nonunion environments
• Training and workshop development for quality, statistics, general manufacturing and technical processes
• Computer application expertise in Microsoft Excel, SAP
Experience/Accomplishments
ESW, Inc. Crown Point, IN 2010 – present
Project manager: Projects including refining and steel manufacturing, ISO 9000 Accreditation
• Developed procedures, work instructions, curricula and training manuals for clients to meet company training and regulatory requirements, such as ISO 9000, 16949, etc.
• Developed customized Excel worksheets for real-time inventory control and optimal scheduling and loading of vehicles
• Developed training plans for Supply Chain group for ISO 9000 compliance.
• Trained employees in procedures to ensure proper understanding.
• Learned and trained employees in use of company-developed software applications.
Middough Consulting, Inc. Toledo, OH 2007–2010
Project Manager, Refining, Quality Inspections, Contractor Supervision
Engineering Projects, Inspections and Management Activities
• Coordinated inspection activities as part of a $40M refinery upgrade program (“Naptha Sim”).
• Coordinated union and non-union inspection, insulation, and scaffolding contractors as well as other specialty contractors to ensure that inspections were completed on-time and on-budget.
• Managed non-conformance (NCR) resolution process from internal audits and follow through to completion utilizing Sunoco and subcontractors as needed.
• Wrote and managed purchase/work orders and tracked to stay within $6.1M budget. Developed real-time tracking system to highlight overages.
• Achieved 100% on-time inspection status for Sunoco's RBI inspection program (>2000 locations) without a recordable injury or OSHA violation.
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OSHA, ISO and Safety Activities
• Developed and presented daily safety meetings to maintain the inspection department's zero recordable incidents status.
• Managed non-conformance (NCR) resolution process from internal audits and follow through to completion utilizing Sunoco and subcontractors as needed.
• Developed and presented daily safety meetings to maintain the inspection department's zero recordable incidents status.
Toledo Metal Spinning Toledo, OH 2002 –2006
Plant Manager
• Managed plant doing $6M annual sales. Primary customers were equipment builders in a variety of industries (Injection molded machinery, food processing equipment, electrical power distribution, military).
• Improved on-time delivery performance from ~80% to 96% through Theory-of-Constraints management methods.
• Responsible for quality assurance and human resource functions. Maintained QC room’s equipment, ensured that MIL standards and ISO 9000 procedures were followed as customers required them.
• Hired, trained, disciplined employees as necessary.
• Implemented and strengthened lean manufacturing and quality practices in a job shop environment, including day-by-the-hour charts, quick die change, and kanban inventory management.
• Led Toledo Metal Spinning to their first Gainsharing payout since program was initiated 2 years prior.
GT Technologies Perrysburg, OH Aug 2001 – Aug 2002
Director of Quality
• Resolved a major sub-supplier quality issue that could have interrupted one of GT's “Big 3” customers. As a result, implemented the sub-supplier's corrective actions across GT facilities.
• Established common, standardized quality metrics for the division (6 plants in US and Canada).
• Coordinated quality efforts at GT Technologies to support overall QS 9000 quality registration.
TG North American HQ Troy, MI Jun 2000-Jul 2001
Quality Manager
• Set up North American quality reporting system to support TG North America manufacturing companies.
• Coordinated quality efforts at TGNA (headquarters) to support overall QS 9000 quality registration.
• Assisted operations as needed in quality training, consulting, and other related support.
• Attended customer quality meetings to discuss issues requiring TG's action and resolution.
Eaton Innovation Center Southfield, MI 1989–2000
Quality Manager 1994–2000
(Responsible for Detroit and Milwaukee locations (~450 people total)
• Led Detroit Center to achieve Eaton Quality Award in 1996.
• Led Detroit Center to achieve Michigan Quality Award “Honor Roll” in 1995 and 1997.
• Initiated implementation of ISO 9001 quality system in Detroit.
• Established supplier audits for key suppliers .
• Established internal audit system for management system review.
• Established Corrective Action and Issue Resolution system to "close the loop" on all open corrective actions in the Center.
• Established quality measures for the center (Cost of Poor Quality, timecard accuracy, project deliverables % complete, delinquent projects).
• Managed EMC lab as a separate “profit center” with annual revenues of $1.3M+ and 15% annual growth.
Corporate Quality Engineer Eaton Quality Institute Southfield, MI 1990–1994
• Developed and delivered 30 workshops per year in quality methods such as Taguchi Methods, Statistical Process Control, Continuous Flow Manufacturing, 8D Problem Solving, ISO 9000, Teaming, and Total Quality Management
• Developed training course for Theory of Constraints based on book “The Goal”.
• Consulted with division manufacturing facilities to implement methodologies post-workshop.
Quality Supervisor Eaton Engine Components Plant Saginaw, MI 1989–1990
• Supervised four (4) plant quality engineers.
• Helped re-establish plant quality system and regain Ford Q1 status after customer audit.
• Developed control plan and procedures for manufacturing process.
• Completed primary analysis of material study seeking alternative material.
Instructor, part-time University of Toledo College of Engineering Toledo, OH 2006 – 2010
• Taught various classes including Facilities Planning, Statistical Design of Measurement Systems, Engineering Economics, Operations Research, and Statistical Quality Control.
• Incorporated Excel spreadsheet application of operations research methods including linear programming, plant layout, and statistical analysis.
Education
• M.S., Manufacturing Management GMI Engineering & Management Institute Flint, MI
• B.S., Industrial Engineering University of Toledo Toledo, OH
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