Paul

A focused quality/lean professional with over 25 years supplier quality, quality systems, quality engineering and lean experience. Qualified to Six Sigma green belt level with solid foundations in systems, process and performance improvement through the application of automotive and aerospace industry derived techniques. A qualified auditor (ISO 9001/ AS9100 plus ISO TS 16949 experience) with a logical approach to process and quality management system improvements and problem resolution.

Project Quality Engineer (contractor) - RFD Beaufort LTD - Ellesmere Port

(2024-04)

Manufacturing of pilot safety systems, submarine escape systems, fast jet pilot ejection equipment, pilot flight equipment

• Manage supplier/ customer FAI and LAI submission process for partner plant product transfer engineering up revisions, new product introduction
• Produce, implement and monitor internal and external non-conformance improvement actions via 8D/ 5 why/ Ishikawa CAPA process
• Customer interface for external complaints management and subsequent resolution via CAPA reporting
• Control in line quality assurance activity through development of robust quality inspection plans
• Coordinate improvement actions for FAVE customer audit activity (BAE)
• NPI quality lead for introduction of new product lines and cross plant product transfer

Project Quality Engineer (contractor) - TT Power Electronics LTD - Dual site coverage- Newcastle/ Manchester

(2020-10 - 2024-03)

Manufacturing of transformers, linear regulators and power converters for high reliability applications in defence and aerospace applications (Airbus A400M).

• Manage sub contractor/supplier First Article (FAI) submission process for over 100 drawn components
• Produce complex LAI/FAI/PPAP reports for new manufacturing site and engineering up-issues
• Validate LR1 production output to drawing and test specification requirements
• Coach production associates in shop floor quality tools (Ishikawa/ 5 why/ 8D)
• Implement key process monitoring controls on shop floor for MIL 883/MILPRF 38535 DESC approval
• Co-ordinate implementation of conformance and validation testing requirements to MIL883

Project Quality Engineer (contractor) - Meggitt Aerospace Controls LTD - Birmingham

(2018-02 - 2020-10)

Manufacturing of fuel/oil heat exchangers for commercial and military aircraft engine applications including Rolls Royce Trent 700/900, CFM 56, Pratt and Whitney 4000

• RCCA Quality lead for raw material source change programme (8D)
• Co-ordinated manufacturing process conformance audits and validation of closure actions
• Produced FMEA and control plan revisions in line with continuous improvement changes
• Coached manufacturing engineering apprentices in FMEA rollout
• Developed site zero defects plan for customer specific project requirements (Rolls Royce, Collins)
• Trained production associates in implementation of ZD tools (APQP)
• Developed product specific defect reduction plan for Safran tube and shell heat exchangers

Senior Supplier Development Engineer (contractor) - TT Electronics – Semelab LTD - Lutterworth

(2014-07 - 2018-02)

Manufacturing of discrete semi-conductors, power inverters, and multi-chip arrays for hi-reliability applications in Aerospace, Automotive and defence markets.

• Travelled extensively worldwide conducting on site Supplier audits and improvement plan rollouts
• Managed component quality verification and test activity, supplier KPIs and process waste reduction
• Reduced net occurrences of supplier non-conformance by 40% in 3 years
• Awarded 2016 TT Electronics Power and Hybrid Group Divisional Employee Award for Excellence

Senior Supplier Quality Assurance Engineer - Survitec RFD Beaufort Group LTD - Wirral

(2010-06 - 2014-07)

Manufacturing of Aerospace and Naval survival and support systems including pilot flight equipment for F35 Joint Strike Fighter and Eurofighter Typhoon GR4.

• Managed supplier performance monitoring and reporting system
• Travelled extensively worldwide conducting on site Supplier audits to ISO9001:2008, AS9100 rev D
• Managed Supplier audit corrective/preventive action activity
• Trained junior engineers in key RCCA processes
• Verified and authorised release of new Production parts utilising Sample disposition process

Leading Quality Engineer - Syncreon Automotive Systems, Vauxhall Motors - Wirral

(2004-07 - 2009-02)

Assembly and sequencing operations of Vauxhall Astra components including engine carriers, rear axles, and suspension and brake modules, for JIT delivery to the customer.

• Co-ordinated Kamishibai Departmental QA process Management system
• Implemented lineside Ishikawa root cause analysis tools across production cells
• Co-ordinated and presented 8D submissions to customer at daily customer focus clinic
• Audited Plant Quality system to ISO/TS 16949 standard
• Co-ordinated departmental KAIZAN activity and led successful Six sigma green belt projects

Process/ Quality Engineer - Lear Corporation, (Jaguar Land Rover) - Halewood

(2003-01 - 2004-07)

Manufacturing and sequencing of Jaguar X- Type front and rear seat assemblies for JIT delivery to the customer.

• Developed and implemented new production processes for US federal market seats
• Set up and managed standard cycle time database for all Plant Production processes
• Rebalanced production processes according to Customer TAKT time fluctuations
• Applied value stream mapping methodology to key processes

Quality Assurance Engineer - Visteon Automotive Europe, (Jaguar Land Rover) - Halewood

(2000-05 - 2003-01)

Assembly and line sequencing of complete Jaguar X- Type cockpit modules, centre console modules and underhood cooling modules for JIT delivery to the customer.

• Represented Company at daily Jaguar Customer audit and presented 8D/ 5 why problem resolutions
• Co-ordinated customer quality responses through Jaguar AIMS system
• Co-ordinated internal and external audit schedule, CAPA tracking and closeout
• Managed all supplier containment and rework activity in plant

Quality Technician/ Quality Engineer - Vauxhall Motors - Wirral (plus 6 months GM Atlanta Georgia USA facility)

(1995-08 - 2000-05)

Manufacturing and line sequencing of over 30 Vauxhall Astra/ Chevrolet SUV interior and exterior modules for JIT delivery to the customer (800 per day schedule).

• Controlled in Plant and external tool calibration activities
• Assisted in conversion of Quality system from BS5750 to QS9000 accreditation
• Assisted with producing standardized work process documentation
• Co-ordinated operator traceability system throughout Production areas

BA (HONS) - Criminal Justice and Criminology - Birmingham City University (1993-08 - 1995-08)

Secondary Education - St. Anselms Christian Brothers College (1985-09 - 1993-06)