SUMMARY OF QUALIFICATIONS
Experience in driving continuous improvement through Six Sigma methodologies and developing and facilitating training in lean manufacturing environment with value stream mapping and 5S; developing and driving quality assurance compliance and improvement, including ISO / QS-9000, TS 16949 systems and interfacing with suppliers and customers. Fabrication experience with injection molding, stamping, and machining. Supply Chain and Logistics skills with customer focus. Excellent written and oral competencies.
EDUCATION
M.S. in Industrial Technology
Eastern Illinois University, Charleston, IL
B.A. in Organizational Communication (Business Administration minor)
Millikin University, Decatur, IL
Certified Six Sigma Black Belt; Qualified Lean Black Belt - Caterpillar, Inc.
ASQ Certified Manager of Quality and Operational Excellence
EXPERIENCE
Caterpillar, Inc. 2011 – 2016
Supply Chain Supplier Performance Engineer – Joliet, IL
Supply Chain Supplier Planning Engineer – Mossville, IL
• Led TCO (total cost of operation) Projects to determine optimal sourcing decision
• Led supplier correction / inventory management during constraints
• Led material shortage resolution for ACSD division
• Managed Stock Authorization Process for Service and NPI; enabler for process flow and constraint removal
• Led teams of green belts for a cumulative documented Six Sigma Value Prop of $50 million;
o Project was a finalist for the Chairman's Award
• Drove $12 million in documented Six Sigma Value Prop in Supply Chain
• Developed and facilitated cross functional & multi-divisional team to determine & implement critical path during resin supply shortage to prevent global shut down of ACSD operations requiring hydraulic seals made from proprietary resin.
• Supported SAP compliance readiness for MACH I
Chrysler, L.L.C 2010 – 2011
Quality Engineering Business Unit Leader – Belvidere, IL
• Optimized operational uptime and throughput though in-line containment
• Led product line support from supplier, application, and dimensional engineering groups
• Led teams in World Class Manufacturing problem solving methodology deployment
• Maintained quality system integrity; optimize labor resources to assure conformance to engineering specifications
• Drove conformance to APQP and NPI schedules; drove safety optimization
Caterpillar, Inc. 2008 – 2009
Supply Chain Black Belt (certified) – Aurora, IL
• Responsible for Standardizing Firm Order Period – Materials Supply Chain
• Green Belt Development; Caterpillar Production System (CPS) training schedule conformance
General Electric Co. 2005 – 2008
Quality & Lean Manager, GE Motors – GE Consumer and Industrial, DeKalb, IL
• Responsible for Quality on NPI (New Product Introduction) projects: 2007 $1 million cost out
• Responsible for Plant Quality: Supplier, In-Process, and Customer
o Supplier – Implemented divisional Corrective Action and Reject Management Programs to reduce local plant burden; drove cost out initiatives from Materials Team
Sought and recommended alternate suppliers for qualification to drive costouts
Modified divisional qualification process to include PPAP components
o In-Process – Led in-plant qualification for new and alternate process validations using Six Sigma methodologies
o Customer – Reduced SCR (Service Call Rate) 35% through joint efforts with Engineering and customer
• Staff Responsibilities for Financial Op Plan and Estimate Drivers; EHS conformance, and Lean
Newell Rubbermaid 2002 – 2005
Sr. Quality Engineer, Amerock Corp. – Ashland Hardware Group, Rockford, IL
• Responsible for APQP deployment on new product launches; instruct teams on QS-9000, TS 16949, and APQP expectation standard for new customer design development projects
• Responsible for in-process and customer quality issues
• Instructed peers and team members on progressive value added quality system methodologies through daily interaction: 8D, VSM, critical characteristics / process control, cost out
• Instructed and mentor suppliers on problem solving, statistical control, and supplier responsibility to attain zero defect level of quality through interaction with purchasing team
• Developed PPAP level submissions with suppliers
Eaton Corporation 1999 – 2002
Quality Engineer, Powertrain and Specialty Controls (ASD), Rochelle, IL
• Responsible for molding, stamping, and machining departments as well as administration of SPC for plant
• Drove internal and external PPM in positive direction finishing under annual goal
• Reduced internal PPM by 70%
• Increased through-put and conformance assurance of components by minimizing lot sizes and coordinating with Kanban levels and level loading schedule
• Value Stream Mapped Fab QA
o Restructured control plans and set-up sheets
Removed boiler plate quality control checks for evolution to quality assurance
Modified quality checks for sensitivity to stroke rate and cycle time
Reduced tool controlled dimension checks during manufacturing process to set-up only resulting in cost savings through minimizing direct labor variance
o Removed fixtures from calibration program
o Minimized layout discrepancy by limiting inspectors used per layout to one
o Reduced auditor work force by 20%
o Restructured (VSM) RMA process to minimize costs
• Deployed auditor training program for QA auditors
• PPAP for all components manufactured in-house for division (including Rochelle plant)
o Assured all back-up tooling was at current PPAP level for emergency use
o Worked closely with schedulers and planner during in-source of free market components and during extension of PPAP restrictions/non-conformances to optimize component throughput and assure line up-time
o Recommended design changes based on tool capability and part application
• Fulfilled manufacturing engineering responsibilities during interim periods: duties included but were not limited to:
o Developed packaging specs
o Modified/created routings and bills of material
o Interfaced with suppliers to assure/correct material specs and verifications
o Developed P FMEAs, Risk Management, and Flows
o Interfaced with divisional design group for product launches, design modifications, and economic corrective actions (i.e., more economical to correct mating part in-house than to have overseas supplier re-tool)
o Performed special stroke rate studies on specific dies and special cycle time studies on specific presses to assure correct scheduling and accurate departmental utilization analysis
o Recommended alternate materials for molding and roll threading
o Championed Roll Threading Project as Greenbelt
Eaton Corporation 1993 – 1998
Quality Engineer, Hydraulics, Carol Stream, IL
Production Manager, Appliance and Specialty Controls, West Plains, MO
ISO 9000 Coordinator, Cutler-Hammer, Lincoln, IL (Mid-States Technical Staffing)
• Responsible for raising quality system integrity at Petersburg facility
• Performed statistical analysis on high running product (A parts) for Six Sigma projects including both continuous and attribute data
• Developed and coordinated training program for new team members based on University of Missouri Quality Technician criteria
• Trained and involved team members in process improvements and system audits
• Improved collaborative interaction effectiveness through Zenger-Miller skills development
• Managed production operations including developing and maintaining budget, reducing rework and scrap, restructuring flow, and capacity planning
• Directed and interacted with cells in JIT-focused factory environment utilizing Kaizen, Six Sigma, Poka-Yoke, TPM, 5S, Zenger-Miller principles, and Kanban with MRP controlling raw materials only
• Co-developed Eaton Quality Award (EQA) application (criteria modeled after Malcolm Baldrige National Quality Award)
• Conducted Keki Bhote DOEs and 8D/fish bone analysis utilizing expertise of work cell members
• Responsible for plant quality measurables, trend analysis, SPC conformance, calibration conformance and traceability, and control chart conformance and modification
• ISO 9000
• Chaired team of six top management personnel that developed ISO 9000 implementation strategy
• Implemented strategies that resulted in ISO 9000 certification on first audit
• Developed and produced instructional manual and co-facilitated ISO 9000 concepts and auditor training to management and work cell members
• Monitored ISO/quality system compliance during and following major product acquisition and product mix change
• Assisted in the development and implementation of quality system procedures in both manufacturing and quality assurance
Supplier Quality
• Helped develop procedures for JIT supplier interface up to and including corrective and preventive measures including follow-up with suppliers
• Responsible for corrective action for customer complaints and supplier problems; included analyzing proper product use and upgrading quality systems at supplier site
• Assisted in modification to receiving/inspection program to identify material upon receipt for point of use, delivery, sampling, 100% inspection, or specific defection inspection
• Assisted in supplier audit for supplier certification
• Assisted suppliers in upgrading existing quality systems to meet certification requirements
Honeywell, Freeport, IL 1998
Quality Specialist
• Improved efficiency of divisional internal audit process by 66% through optimizing capacity utilization and eliminating non-value added elements
• Identified and fostered implementation of best practices of quality system including Malcolm Baldrige,
• D1-9000, ISO 9001, and QS-9000
• Statistically analyzed continuous and attribute data to drive out variance in both production and administrative processes
• Championed benchmark of EHS and Quality System Database for integration of ISO 14000
• Championed quality mentoring of suppliers (SQA) utilizing Six Sigma tools in conjunction with commodity management team
SPECIAL SKILLS
• Instructing: Problem solving: 8D, 5 Whys, Fishbone
• Zenger-Miller deployment, Six Sigma, CFM/VSM, Kanban, Triz, 5S
• Mini-tab, AS-400
• Standards: QS-9000, CSA, UL, MBNQA
• Automotive Experience
• Fabrication Experience
• Molding
• Stamping
• Machining
• Plating
• Powder Coating
• Heat Treating
PROFESSIONAL DEVELOPMENT
• Certified ASQ Quality Manager (CQM) certification: 10/02
• Officer: American Society for Quality
o Executive Board 2003-2007; four year progression to chairman
• Certified in ISO 9000 Documentation Control and Lead Auditor
• APICS (American Production and Inventory Control Society) CSCP (Certified Supply Chain Professional)
o Review Class completed; APICS qualified to sit for exam
• District STEM Chairman, Boy Scouts of America
• Committee Member for Interviewing School Board Superintendent Candidates
