Quality Engineer /Manager
Resume:
Thomas K. Barry
**** **** ********** **** *****
West Bloomfield, MI. 48324
*********@*******.*** / *********@*******.***
OBJECTIVE
Desire a career path to integrate my manufacturing, quality, purchasing leadership skills and knowledge to facilitate activities to drive supplier strategy in resolving quality, design, and production manufacturing delivery issues. Seek opportunity to supervise teams, develop suppliers on ISO/TS/QS initiatives to support the resolution of process related issues and cost objectives.
CAREER EXPERIENCE
Ford Motor Company - FCSD (Contract Assignment)
5/2009 – Present
Dearborn, MI.
STA Engineer - Resourcing Specialist
Accomplishments: Obtain and resolve critical engineering drawings, part releases, tooling, purchasing distresses suppliers and process issues with critical Ford suppliers. Provide assistance and direction to achieve optimum of cost, quality and delivery targets. Ensure systems and processes are effective in producing and delivering parts that meet service quality, cost and schedule requirements. Responsible for the monitoring and review supplier APQP activities (control plans, PFMEA, process flow, SPC, run at rate, PPAP, etc.) and ensure processes are completed to Q1 Ford standards and delivered on-time. Assist suppliers in problem solving effectiveness including root cause analysis through implementation of corrective actions. Conduct supplier assessments MSA --for potential new suppliers. Work with suppliers to develop continuous improvement plans and metrics to monitor performance. Lead supplier Ford APQP kick-off meetings and supplier design reviews. Participate, as needed, on Ford PDT teams and effectively interact with other Ford technical departments and Assembly Plant personnel. the development, management activities, and priorities of a service part suppliers. Develop teams that will improve supplier processes to support and facilitate low cost sourcing negotiations on critical parts and programs.
Dana Corporation – Torque Traction Integration Technologies
02/2008 – 04/2009
Auburn Hills, MI.
Plant Quality Manager
Accomplishments: Drive improvement in plant quality performance: warranty, customer PPM’s, internal PPM’s, scrap, etc. Ensure the quality team is fully qualified and consistently exceeding expectations. Plan aggressive plant quality objectives and drive the action plans to achieve those objectives. Ensure corrective action processes are comprehensive, fast and cost effective. Ensure all new and changed products are fully validated for compliance and capability prior to implementation, and proper approvals. Ensure all new and changed processes are fully validated for compliance and capability prior to implementation, and proper approvals. Maintain required or desirable plant certifications and compliance to: ISO/TS 16949-2002, all customer specific requirements Monitor supplier quality and hold suppliers accountable for product which is not compliant and work with supplier development on consistently problematic suppliers. Communicate performance and critical issues appropriately through the organization, customers and suppliers.
Ford Motor Company – FCSD (Contract Assignment)
10/2006 – 01/2008
Dearborn, MI.
Program Manager Six Sigma - Quality Cost Reduction
Accomplishments: Developed project plans, work breakdowns structures, and establish product schedules and resolve timing issues on re-core salvage component parts. Facilitate the direction and assistance to re-man unique suppliers in order to achieve compliance to ISO/QS9001 system requirements. Identify process improvements and develop cost reductions proposals for engines and transmissions. Interface with Program Engineering, Supplier Technical Assistance, Manufacturing, Purchasing and Quality. Lead Six Sigma project improvements and present finding to senior Ford management. Manage suppliers and present cost saving reductions to senior Ford management.
Chrysler - MOPAR (Contract Assignment)
11/2005 - 8/2006
Center Line, MI.
Senior Quality Cost Specialist
Accomplishments: Provide direction on the development and approval of MOPAR remanufacturing suppliers and coordination of process improvements and engineering changes. Review, develop, verify, sign -off on supplier's PPAP PSW and PSO strategy for production of MOPAR service parts. Approve and verify control documentation, D/PFMEA, DVP&R, and Manufacturing Process Flows, Control Plans, Work Instructions, Process Improvements, Tooling Equipment, Gages, Process Monitoring and Planning, Warranty and 7 Step problem solving corrective actions.
ELOPAK Precision Machining
10/2004 - 9/2005
Walled Lake, MI.
Corporate Quality Director
Accomplishments: Responsible for quality management within the Elopak community and minority sources. Directed the establishment of new robotic production process and improvements on casting and specialized aluminum components. Develop the advancement of PPAP quality practices to obtain approvals on APQP activity and PPAP submissions for the plant.
Fujitsu Ten Corporation (Contract Assignment)
5/2003 - 10/2004
Plymouth, MI.
Corporate Quality Program Manager
Accomplishments: Responsible for management of all GM APQP & PDT launch activities for GM250 audio program. Create BOM, DFMEA's, R&R, Flow Charts, Pre-launch Control Plans, DVP&R testing for PPAP submissions and PDT meetings. Coordinate Program Management and supervise activities to ensure products meet customer expectations and MS Project quality objectives. Represent corporation to resolve design and manufacturing issues.
Sanyo Corporation
4/2002 - 5/2003
Novi, MI.
Quality Manager / Program Manager
Accomplishments: Provided the management and direction of quality continuous improvement efforts for Sanyo North America operations. Provide on site direction for successful program launch implementation. Support procedural execution of initiatives to increase productivity, reduce scrap cost, and enhance process quality. Represent corporation to resolve quality design and manufacturing issues. Pursue root-cause, corrective actions, and continuous improvement activities with OEM customers.
Moller-Tech
6/2001 - 2/2002
Shelby Township, MI.
Plant Quality Manager
Accomplishments: Oversee the supervision of quality staff production personnel, and facilitate production control activities for plant. Maintain quality systems and QS/ISO certification and internal quality audit activities. Pursue corrective action and continuous improvement efforts on internal and external concerns and issues.
Lear Corporation - GM Warren Division
10/2000 - 5/2001
Mound II - Warren, MI.
Senior Corporate Program Quality Engineer
Accomplishments: Evaluate the PPAP packages of external suppliers to confirm the documentation is accurate and meets expectations. Coordinate DVP&R testing and product validation to GM specifications.
Johnson Controls, INC. (Contract Assignment)
7/1999 - 9/2000
Warren Integration Center Warren, MI. (Contract Assignment)
Senior Program Launch Quality Engineer
Accomplishments: Support APQP meetings and coordinate quality activities for electronic instrument panel during launch of vehicle. Develop and maintain PPAP activities, control plans, flow charts, and D/PFMEA's. Contribute corrective actions root cause analysis to design issues.
Kelsey-Hayes – Lucas Varity
5/1992 - 4/1999
Milford / Fenton / Livonia, MI.
Plant Quality Manager / Senior Quality Engineer / Senior Engineering Quality Liaison
Accomplishments: Supervise and support staff in quality production activities championing opportunities for improvement of machined aluminum ABS brake components in the plant. Serve as lead auditor to facilitate the maintenance of QS9000 requirements for the plant. Direct customer resolution and process corrective actions.
EDUCATIONAL BACKGROUND
Eastern Michigan University, B.S. PSY-Industrial Technology - Quality Management - Six Sigma Green Belt
Central Michigan University, Masters in Business Administration - Management and Supervision
Certified QS/ISO Auditor / Lead Assessor – RAB
PROFESSIONAL SUMMARY
I have prior career history with AM General Aerospace and Defense as a Reliability Engineer and launched the HUMMVI for the military. My experience is in supplier/OEM environment with strong knowledge of manufacturing processes and production environments. Have extensive experience and technical knowledge of ductile, grey iron and aluminum castings. My quality exposure has been in Electronic Audio Components, Power-train systems, ABS Brake Modules, Chassis Components, Prop shaft, Torque Converters, High Speed Precision CNC Machining, Casting Knuckle Hub Machining, Lathe, and Boring Machining, Plastic Injection Molding of Interior Trim components, A-Pillar, B-Pillar, C-Pillar, I/P, Headliners, Cargo accessories, Seating components Electronic Modules, Instrument Panels, Exterior Fascia, Electromechanical Devices, Engine Control Modules, Audio Systems Integration, Electronic Clusters, Speed Sensors, Vehicle Integration components. I am fully trained in DOE methods, GD&T and advanced GD&T concepts. I have extensive background in supply quality management, program management, and demonstrated production manufacturing leadership skills in QS9000/TS16949/ ISO management implementation. I have facilitated numerous process quality, purchasing, production and engineering activities to resolve design warranty and process issues. I am fully trained in all aspect of quality management and have outstanding interpersonal skills and team building skills. My background is in developing processes for DVP&R PPAP submissions for APQP and current production components in regards to product/process changes. I have also resolved numerous cost improvements for process issues on purchased components and documentation such as process flow diagrams, control plans, PFMEA’s, RPN reduction plans, gage plans, gaging, error/mistake proofing, work instructions, handling of nonconforming material, and other quality related areas. I have performed on-site technical and quality system audits/assessments of suppliers and processes. Facilitated plant ISO 16949 certifications, open issues list and manage until issues are fully resolved. In addition I have lead teams to ensure proper containment, root cause analysis, and corrective action implementation and verification. I have performed run at rates, tool moves and capacity reviews, for launch readiness reviews at various plant / supplier locations. I have facilitated regular meetings with internal/external suppliers, regarding process control, and measuring the effectiveness. I have proactively developed suppliers on continuous improvement initiatives and successful implementation. I have also resolved numerous process issues on purchased components in areas such as process flow diagrams, control plans, PFMEA’s, RPN reduction plans, gage plans, gaging, error/mistake proofing, work instructions, handling of nonconforming material, and other quality related areas. I have performed on-site technical and quality system audits/assessments of suppliers and processes.
Highly motivated individual and have facilitated open issues list and supervised teams until issues are fully resolved. In addition I have supported APQP and ensure proper containment, root cause analysis, and corrective actions are implementation and verification of data statically. I have proactively developed OEM suppliers on continuous improvement initiatives and successful zero ppm implementation. During my career I have provided program management, supervision, supplier development, and OEM program purchasing launch support. I have approved and developed PPAP warrant deliverables, for successful program launches and facilitated liaison activity for product-engineering teams. I have six sigma training and experience making significant process and cost reduction improvements.
COMPONENT EXPERTISE:
Prior experience with Ford Motor Company as a Buyer with component expertise in the following commodities: Plastic resins, Raw materials, Electronic ABS Brake Modules, Drive shafts, Power train, Chassis Components, Torque Converters, High Speed Precision CNC, Casting Machining, Lathe, and Boring Machining, Plastic injection molding of interior trim components, A-Pillar, B-Pillar, C-Pillar, I/P, Headliners, Cargo accessories, Seating components Seat heating modules, I/P deployment testing, Exterior fascia, CD Audio, Electromechanical devices, Engine control modules, Audio systems integration, Electronic I/P Clusters, Speed sensors, Window regulator systems, Chassis modular cradle components. Trained in DOE methods, GD&T and advanced GD&T. I have extensive background in supply chain management, quality management, warranty administration, re-man salvage operations and demonstrated production manufacturing leadership skills and knowledge of QS9000/TS16949/ ISO management implementation requirements. I have provided MS Project program management, supervision, supplier development, program launch support.
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