8498 Shady Trail
Bessemer, AL
 [Send email to request phone number] 25-6337

Summary of Qualifications

Over 20 years of experience in Quality Assurance and Manufacturing, most in the
automotive industry. Six-Sigma Green Belt trained in Kaizen, BBP (Best Business
Practice), Lean Manufacturing and One-Piece flow. Proven ability to reduce
internal / external PPM and costs while improving efficiency and productivity.
Excellent ability to develop working teams to achieve goals within established
timeframes. Significant experience dealing with customers to improve overall
relations. 

PROFESSIONAL EXPERIENCE

 
OPERATIONS MANAGER July 2007 - 2009
CONTINUOUS IMPROVEMENT / LAUNCH MANAGER 
Plastech *  McCalla, AL (Automotive  *  Injection molding and assembly)
Johnson Controls Interior Manufacturing
 *  Reduced past due parts from 200,000 pcs to 30,000 pcs in 4 months.
Eliminated all past dues in 6 months. 
 *  Responsible for plant cost saving goals from Lean Manufacturing / Kaizen
projects of $3.5 million/year.
 *  Improved plant schedule attainment from 50% to over 70%.
 *  Increased plant headcount from 74 direct operators to 168 due to increase in
business
 *  Decreased O.T. due to increased efficiency 
 *  Transferred and launched 170 current production GM tools within 90 days
 *  Improved production reporting accuracy to reduce quarterly inventory
variances from $300.000 to $15,000
 *  Responsible for transferring 4 Honda door assembly lines from JCI - Canada

QUALITY ASSURANCE MANAGER Feb 2006  *  April 2007
Burner Systems International  *  Chattanooga, TN (Appliance - Gas supply
tubing)
 *  Reduced external corrective actions from 77 to 8 in five months by involving
a team approach
 *  Plant PPM reduced by over 60% in 13 months
 *  On-site support for the two largest customers on a weekly basis resulting in
improved customer satisfaction 
 *  Lead QA Manager for three plants in North America

QUALITY ASSURANCE MANAGER / OPERATIONS October 2003  *  Jan 2006
Plastech Engineered Products  *  McCalla, AL (Automotive  *  Injection molding
and assembly)
 *  Worked in Michigan for first three months planning new plant operations
including; plant layout, material flow, and floor operations for 50 presses and
assembly operations
 *  Filled in for Plant Manager during absences from the plant including daily
updates to owner of company focusing on daily financials, delivery, and customer
satisfaction
 *  Ran daily production floor operations during gap of Operations Manager
 *  Launched 4 new programs with over 250 tools for end users including
Mercedes, GM, and Hyundai
 *  Assisted with day-to-day plant operations including daily production,
scheduling, inventory control, engineering samples/changes

QUALITY ASSURANCE MANAGER March 1996  *  June 2003
Lear Corporation - Dayton, TN (Automotive  *  Injection molding and assembly)
 *  QS-9000 / TS16949 & ISO14001 Trained Internal Auditor
 *  Six Sigma - Greenbelt
 *  Managed Three Quality Engineers, 22 Auditors/Lab Techs, One CMM Operator, &
One QS9000 Lead Auditor/SPC Coordinator
 *  Led efforts to achieve QS9000 & ISO14001 Certification
 *  Assisted in launch of $36 million new program (doubling size of business)
 *  PPM reduction over last three years  *  from 56 PPM to 11 PPM on 12 million
pieces shipped
 *  Responsible for cost recovery program for Incoming Inspection that netted
$150,000 annually

 Merrill Smith  *  page 2

QUALITY ASSURANCE ENGINEER May 1994  *  March 1996
Lear Corporation (United Technologies Automotive)  *  Dayton, TN
 *  Responsible for warranty evaluations 
 *  Involved in all aspects of launch of 3 new programs and transfer of 3 other
programs
 *  Investigation and resolution of customer field issues
 *  Wrote control plans, FMEAs, and annual validation tests for programs
 *  Responsible for Incoming Inspection and Supplier Development

QUALITY ASSURANCE DIRECTOR May 1992  *  Mar 1994
Creative Plastic Molders  *  Lexington, N.C. (Custom  *  Injection molding and
assembly)
 K & K Plastics  *  Ayden, N.C. 
 *  Administered overall quality systems at both plants
 *  Directed preparation of customer surveys for companies including Black &
Decker, 
PPG, and Hallmark
 *  Established standardized quality criteria through direct customer contact
 *  Implemented and trained employees for an SPC program at both plants

QUALITY ASSURANCE MANAGER June 1989  *  May 1992
 Nyloncraft - Hickory, N.C. (Automotive  *  Injection molding)
 *  Achieved Ford Q1 Award in 3 months time
 *  Received    Excellent    rating from customers including TRW, Bosch Power
Tool, Bosch Automotive, Excel Industries, and Saginaw Steering
 *  Established Quality Operating System (QOS) per Ford guidelines
 *  Managed six inspectors, one layout technician, and one QA Supervisor/ SPC
Coordinator

QUALITY ASSURANCE ENGINEER May 1987  *  June 1989 
 Applied Composites  *  Hartford City, IN (Automotive  *  Compression molding
and Paint)
 *  Interim Quality Assurance Manager
 *  Liaison between company and General Motors
 *  Responsible for quality system rated    Excellent    in GM and Chrysler
supplier audits
 *  Wrote lab manual for a GM-certified laboratory
 *  Scheduled and conducted all vendor audits

EDUCATION
Studied toward: Bachelor of Science in Industrial Management / Industrial
Engineering (IMIE), Purdue University, West Lafayette, IN

 
SPECIAL TRAINING
Lead Internal Auditor for QS-9000, TS-16949, ISO14000
Six Sigma  *  Greenbelt
Lean Manufacturing / Kaizen
Design of Experiments (DOE) of Taguchi Methods
Customer Problem Solving Techniques  *  Ford and Chrysler
Operation and programming of Brown & Sharp, and Mitutoyo CMM software