Quality & Reliability Consultant
Ford Motor Company
Total years of experience :33 years, 2 Months
I supervise a team of 3 engineers in R&D working to ensure achieving high quality, reliability and cost targets of newly developed vehicles programs.
Responsibilities:
• Set policies and procedures on quality strategy and performance management
• Apply quality analysis tools to confirm root causes and establish preventive actions.
• Update Quality Management System, corporate documents and procedures.
• Lead continuous improvement to meet quality and cost targets.
• Establish key performance indicators (KPI) and provide feedback and advice to senior management.
• Analyse corporate performance, identify opportunities for improvement and draw action plan.
• Lead deployment of the organizational excellence and Best in Class models (BIC).
• Assures vehicles are designed and built to meet or exceed all applicable laws and requirements.
• Advances the state of the art in safety wherever possible.
• Ensures company has timely access to required environmental, safety and homologation information and representation in growth markets.
• Assures company remains competitive in Vehicle Safety.
• Ensures all activities are fully informed of vehicle safety regulations, and understand them.
• Works with government and industry to avoid, where possible, inappropriate safety regulations.
• Promotes appropriate new safety regulations, consistent with Ford's safety vision and business interests
• Handles government safety inquiries.
Olympus is a worldwide supplier of medical equipment and devices. Reporting to manufacturing director, I lead a team of 4 engineers and 60 operators working in manufacturing operation.
Responsibilities:
• Manage production (line and made-to-order) and ensure meeting customer orders within budget and resources.
• Monitor business performance measurement through KPI and recommend corrective action to meet targets.
• Monitor compliance with H&S standards and carry out periodic Health & Safety risk assessments.
• Develop employees and productivity via training, periodic competency assessment and appropriate training.
• Lead continuous improvement of manufacturing operation/processes for quality, cost, and delivery.
• Design and set-up of assembly line/tools and introduce new products to manufacture.
• Issue standard work instructions, conduct Motion and Time Studies, ergonomics studies.
• Issue standard operating procedure and ensure compliance with ISO9001, TS16949, ISO 13485, 21 CFR.
• Deploy lean manufacturing principles (TPS)/Six Sigma practices.
Achievements
• Reduced product cost by 58%.
• Reduced manufacturing standard time by 70%.
• Completed Six Sigma project that saved £300, 000 per annum.
• Won the ‘MOST IMPROVED FACTORY’ award in 2009.
Visteon is a global supplier of automotive parts. The plant was specialised in machining, and assembly of Aluminium products. Reporting to the plant manager, I supervised 7 engineers and 60 operators.
Responsibilities:
• Lead continuous improvement of processes and materials to reduce cost, lead time and improve quality.
• Improve assembly methods to satisfy ergonomics and Health & Safety requirements.
• Source/ purchase new tools, machinery and equipment.
• Manage contracts and outsourced work to ensure achievement of specifications within budget.
• Deploy lean manufacturing/Six Sigma practices and lead staff training.
• Develop performance measurement method, monitor and improve performance.
• Lead failure mode analysis projects and problem solving teams.
• Carry out internal quality audits to ensure compliance with procedures and industry standards.
• Manage manufacturing operation on night shift (alternating shift pattern).
Achievements
• Installation of 3 new production lines and introduction of 3 new products from design to manufacture.
• Completed a value stream improvement project that reduced lead time from 8 to 3 days.
• Successfully completed a Six Sigma project that reduced rejects from 24% to 3% and saved 270K/year.
The company is one of the leading car manufacturers in the world. Reporting to the regional quality manager, I supervised 3 engineers in R&D working to ensure high quality of a newly developed car projects.
Responsibilities
• Develop customer needs, wants into design requirements using QFD and KANO model.
• Address quality issues and implement corrective action using problem solving tool and six sigma.
• Analyse quality performance data and set new quality and reliability targets.
• Carry out reliability & robustness studies on potential quality issues.
• Apply Reliability & Robustness tools (Boundary Diagram, P-Diagram, FMEA, DVP&R, and Control Plans)
• Project manages the program via the Advance Product Quality Planning (APQP).
• Monitor supplier development program and carry out suppliers auditing.
Radial is a telecommunication component manufacturer specialised in coaxial and fibre optic cables. In 2002 the company closed their plant in the UK and moved to China. I was reporting to the general manager, I managed the manufacturing operation on night shift which included a team of 40 employees.
Responsibilities:
• Develop new processes/tools for new products.
• Continuously improve processes to meet quality, cost, lead time targets.
• Capacity and manpower planning, training of employees, implement H&S and environmental policy.
• Manage value stream and inventories level to ensure availability of materials for production.
• Control level of consumable spending/usage for operational requirements against planned budget.
• Manage production and ensure on time delivery of products to customers.
• Member of a cross functional plant management team that monitor achievement of business objectives.
Achievements:
• Completed 6-Sigma project that reduced product variability and scrap/rework by 95%.
• Lead a value stream analysis project that increased production output of fibre optic cables by 150%.
• Established a new Quality Management System for the company based on ISO 9001:2000.
Arvin is tier 1 automotive component manufacturer. The main processes in the factory are assembly, metal fabrication and robotic welding, reporting to the plant manager. Managed 60 employees on night shift and deputised for the plant manager.
Responsibilities:
• Plan and provide production resources based on estimated customer demand.
• Plan introduction of new products, validate new process/equipment via APQP.
• Improve quality, lead time and cost using KAIZEN, VSA and Lean manufacturing (TPS) principles.
• Control of inventories, raw materials, consumables, spare parts using KANBAN systems.
• Apply TPM, OEE to maintain tools/equipment and improve their effectiveness.
• Schedule production runs and volumes and ensuring JIT delivery to customer’s production line.
• Conduct internal quality audits, deal with customers’ complaints, and report daily to plant managers.
Achievements:
• Established a TPM system (Total Preventive Maintenance).
• Key member of the team achieved Q1 Award in 1999.
• Key member of the team won the European Quality Award in 1997.
CCG was a food products manufacturer specialised in ready meals and raw food for the catering industry. I was the manufacturing engineer reporting directly to production manager.
Responsibilities:
• Processing and packing of vegetables, meats, poultry, fish, dairy products and jams.
• Controlling storage of product under correct conditions, and maintaining supply of raw materials.
• Quality control and hygiene of food products under industry regulation (HACCP).
• Maintain equipment and ensure availability of resources to meet customer demand.
MSc. Energy Engineering
B.Sc. Mechanical Engineering