APQP/SQA Engineer - Corporate Engineering Dept.
Currently working on several new programs. DaimlerChrysler PT-44, DR/DE, GMT-360, GMX-315, PL-41, etc. Three successful launches in the past year, also recently completed PSO for PT-44 program, continuing launch support at Toluca Mexico Assembly Plant (TAP).
APQP Quality Engineer - Corporate New Product Engineering Department
November 21, 1997 - August 26th, 1999
Hired on a Contract basis to trouble shoot Extrusion Line processes and establish process controls.
Accomplishments: Statistical analysis and DOE's on processes and raw material correlation's led to the discovery of a material parameter affecting process stability and product quality. This material characteristic is now considered critical and used to determine acceptability of raw material. Lead Internal Auditor for QS-9000 internal audit prior to Registrar's surveillance audit. Led 5 person Audit Team. After completion of project was moved to opening in Corporate APQP Engineering - New Product Development
Quality Assurance Manager - August 26, 1995 to November 13, 1997
GP-10 Accredited Lab Manager - Load, Tensile, Hardness, Fatigue Testing.
1996 - 70% Scrap reduction through implementation of scrap reporting and tracking system,
QS-9000 Registration, 0 PPM to GM and major downward trends in PPM's to all other customers while maintaining a "No Final Audit" - Quality at the source philosophy.
SPC training for 95% of work force. Including Management team completed.130 Level 3 PPAP's completed. Several Prototype (GP-11) submissions. Comparable numbers in 1997.
1997 - Continued 0 PPM and Major improvements in quality. Install new Larson and Carlson load testers, programming them for more efficient audits by operators and layout Technician. Install a Real Time SPC monitoring and gaging network on the shop floor in 4th Quarter. Maintain 0 PPM rejects with improvements in systems, poke-a-yoke, scrap and rework. Audit & work with material suppliers to improve incoming raw material quality.
Machining: Centerless and Blanchard Grinding, Broaching, Thread Rolling,
CNC Lathes and Mills, ACME Screw Machines, Assembly.
Assistant Quality Control Manager - September 1990 - August 1995
Met Lab Manager - Micro Hardness Testing, Plating Thickness, Mag Particle inspection (Level 2 certification).
Started in the Aluminum Die Casting Department as a machine operator, promoted to setup, then Group Leader. Transferred to Injection Molding Dept. as Group leader. Lateral Promotion to Q.C. Technician (supervisor training program) 1981. 1982 - Production supervisor of Parts finishing (deburring) improving efficiency from 50% to 100% + in first 3 months, maintaining 100% efficiency through 11/2 years in dept.
Supervisor of 2nd & 3rd shifts (30-60 personnel) all depts. machine
shop, die casting, Automatic Screw Machines, Tool Room, Q.C., Maintenance,
assisted with start up of CNC Machining Department.
Metrology Lab Setup, CMM's, Roundness Testing, Optical Comparators,
Mag Particle Level 3 Certification, Load Testers, Wire Tensile Testing,
Metallagraphic sample preparation, Micro Hardness Testing , Rockwell Hardness - Brinell, Micrometers, Calipers, Bore Gages, Indicators, Surface Plate Layout, LVDT's Gaging systems, Automated Data collection systems, Geometric tolerancing interpretation and gage concepts, profilometers - surface finish testing, Inspection audit sampling techniques, TQM, SPC, Poke-a-yoke, Kaizen.
QS-9000, ISO 9001/2 Certified Internal Quality systems Auditor, APQP, Supplier auditing, Supplier Development, Continuous Improvement, Problem Solving (Juran), Quality Circles Leadership, Process Trouble shooting, SPC Trainer, QS-9000 / ISO-9000 Training and Implementation, PFMEA, Control Plan, & Procedure development, JIT, MRP, CIM, Excellent People, Team building, Problem Solving Skills.
Software: (able to learn any on short notice)
MS - Word, Excel, Publisher, Lotus smartsuite, Word Perfect 5-6.1 (Correl 7.0)
HTML Publishing (Web site design) Internet access - Netscape 1.0-7.0
Gage Calibration and Recall - Pro Gage, Gage Cal, PQ systems Gage Pak and R&R
Harrington - Cost of Quality (Dos and Windows) SPC - Data Net, SPC 1-3, Mituytoyo
Aluminum / Zinc Die & Sand Casting:
250-900 Ton Machines
Machine Setup, process and die trouble shooting, die maintenance, Vibro
Chromate conversion coating line, precision sanding processes (Flatness within .001")
50-650 Ton Machines
Mold repair and maintenance, machine setup and trouble shooting,
compression molding, rubber extrusion and materials testing.
Machining (Ferrous and Non ferrous materials):
Tool Room Equipment, CNC Programing,
Drill, Tap, CNC Lathes, CNC Machining centers
Automatic Screw machines: ACME 6 spindles, Davenport 5 spindles, Index B-60 & C29's Browne and Sharp single spindles. Vertical and Horizontal Broaching, Thread Rolling, Gear cutting / Hobbing,
Centerless Grinding, Between Center Grinding, Blanchard Grinding,
Light Stamping / Forming - Four Slide and Multislides, Wire forming, Spring making
Deburring - manual, Roto Finish-Ball Burnishing, Ceramic Vibratory,
Flat Lapping (within 0-3 light bands)Vapor Degreasing, Dip and Spin Paint systems, Electro Plating, Anodizing, Phosphate Coatings, Thermal setting resin - aluminum casting impregnation system
Silicone application on Rubber extrusion - wipe, spray, robotic.
Assembly - Line, sub-assemblies, service kit building , complete air cylinder assembly.
Cryogenic / Heat Shrink fits, Presses
Additional: Michigan State Certified- Fire Fighter I & II, EMT