•Was part of a team that successfully launched on time which resulted in 12 months PPM <>
•Collaborated with team members in resolving the greatest warranty failure. Component breakage in the field occurred as well as internally. Taking the lead by testing assembly components, an evaluation was made to move forward with the placement of subcomponent parts. As a result, the customer has not reported any failures.
•Water management and false reversal issues lead to containment at the end of the line. Four people per shift on two shifts were placed online to rework finished goods. For several years, Inalfa absorbed more than $1.2 million per year in rework. When given the task to resolve the issue, containment was eliminated several months later. Since the implementation, Company began to profit more than $750,000 up to date. No reported water leaks and anti trap failures reported.
•Quality management (OEM) began complaining of noisy modules during sunshade operations and of other miscellaneous claims. Warranty data for noisy sunshades were more than 50% of claims and contributed to a high 2.78 monthly rating, which was well over the acceptable target of 1.00. Yearly charge back was estimated to be well over 2 million dollars. Challenged with resolving 100% of claims, I was able to drive the points lower than 0.11 in six months tuning existing parts. Estimated savings between 2014/2015 will be more than $2 millions. Colleagues were working independently redesigning the components, which required new tooling that would have cost Inalfa over $360,000. In addition, saving which would have included the pitfalls of introducing new components to the system, labor involved to tune components and most importantly introducing new potential issues to the product.
•Developed and maintained good relations with customers. Performed effective quality improvements, which contributed to being awarded six new programs.
•Awarded a third program, which contributed to two main failures. One issue was a clicking noise and the other being a ratcheting noise. The other programs implemented fixtures to resolve the clicking noises which was estimated to be roughly $18,000. I was able to root cause the noises in a matter of days. The design feature required on the component required a modification. The end result of the engineering solution eliminated the noises. In addition, the ratcheting noise was root caused to be a miss-alignment of components. Print GD&T callout of one of the components was updated and supplier kicked off to make the adjustments. Once part was modified, the issue was eliminated.
•Supported BMW and Fiat-Chrysler programs in sustaining product and meet customer standards
•Communicated engineering design changes and progress updates to customers in weekly meetings
•Developed stack-ups for design feasibility which include geometric dimensioning and tolerance
•Design and or modify parts and mechanisms for existing programs to enhance feasibility
•Created/implemented temporary work instructions for operations in support of short term containment
•Test (PV/DVP&R), verify and validate parts and executed effective engineering solutions
•Performed line trial on modified components prior to endurance testing to ensure functionality
•Identify cost saving opportunities (VAVE)and initiated cost reduction projects
•Work with quality, suppler quality and manufacturing staff to resolve machine and part quality issues
•Issued quality alerts when non conforming parts are found internally or externally
•Leading root cause and analysis activities for quality spills found at customers facilities
•Conducted kick-off reviews with team members and processed changes to update drawings/BOM
•Willingness to work in all areas assigned as deemed necessary for the success of the team
•Sustained internal documentations and followed protocol procedures, which include submitting DWR's, test lab requests and One pagers (PP slides capturing root cause, ICA and PCA)
•Evaluated SPV test failures and test reports to determine root cause of part defectiveness
•Worked with internal and engineers abroad for design communization and recommendations
•Participated in Gate Reviews, Task Force activities, PLT, and VAVE meetings and activities
•Conducted PTR's when part changes are implemented and orchestrated PER with customers
•Collaborated with purchasing, logistics, materials and the warehouse department in order to progress all activities which may contribute any road blocks which will delay the target dates
•Deliberated capability studies from quality reports and suppliers to if parts meet specification
•Performed kick off reviews with suppliers to ensure key functions and tolerances are met
•Lead internal corrective actions related to processes to ensure controls are followed, such as ensuring gages are certified, control plans, PFEMA, work instructions are updated
•Participated in multiple R@R and launches where meeting minutes were captured and corrective actions enforced to ensure a successful and sustainable program
•Direct involvement in Launch Readiness Reviews and Gate reviews from a sustaining standpoint
•Updated Layered Process Audits (LPA) & End of Line (EOL) checks based on quality issues
•Lead customer audits which include: the preparation of customer deliverables, production line tours, 5S activities, address all customer quality issues in a presentation (RCA/ICA/PCA), improvement proposals, KPI charts, and warranty concerns
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