Blake Kavanaugh
White Lake,MI
Summary
Results-driven professional with a 19-year track record in the automotive industry, emphasizing customer satisfaction. A proven leader and adept problem-solver committed to optimizing operations to reduce expenses and enhance organizational effectiveness.
Overview
18
18
years of professional experience
Work History
Senior Advanced Quality Manager
Magna Seating
Novi, MI
12.2022 - Current
- Oversaw the launch of programs for Ford, General Motors (GM), Stellantis, and BMW in North America, leading a team of advanced quality engineers and specialists in reverse Potential Failure Mode Effect Analysis (PFMEA)
- Excel in executing program launches for both new and existing facilities, ensuring all customer-specific requirements and specifications were thoroughly assessed.
- Guarantee the prompt execution of the Production Part Approval Process (PPAP), the readiness of plant Quality Operating Systems (QOS), and the development of the quality team
- Monitor North American quality Key Performance Indicators (KPIs) related to customer complaints, costs linked to poor quality, a repository of best practices, and the analysis of customer complaints across multiple systems.
- Manage global master PFMEA templates for various commodities, including seat complete, structure, foam, and trim, collaborating with the APQP team to ensure plant compliance.
- Enhance quality processes to boost efficiency and effectiveness within the organization.
- Evaluate products and guide non-conforming items.
- Adhere to quality standards and procedures by developing process specifications to reduce errors and enhance customer satisfaction.
- Elevate customer satisfaction by strictly following quality standards and fulfilling customer requirements.
- Revise quality control standards, methods, and procedures to align with compliance mandates and conducted evaluations to identify and resolve quality issues.
Quality Manager
Magna
Auburn Hills And Detroit, MI
11.2017 - 12.2022
- Responsible for overseeing customer satisfaction in the GM and Ford business units
- Oversaw on-time PPAP activity with the customer, appearance reviews, Supplier Readiness Valves (SRVs), and run-at-rates
- Led presentations to support IATF 16949 compliance standards by building knowledge with supplier quality engineers and technicians
- Managed business unit KPIs, driving action plans to sustain or improve overall performance.
- Maintained departmental workload to support the success of both business units
- Led the plant Business Transfer Approval Board (BTAB) move for the GM and Ford business from Highland Park to Auburn Hills
- Led activity with no customer incidents in the calendar year of 2020
- Improved quality processes for increased efficiency and effectiveness by identifying and addressing bottlenecks in the production line, implementing new quality control measures, and fostering a culture of continuous improvement by following quality standards and procedures to minimize errors and maximize customer satisfaction
- Achieved successful IATF 16949 compliance standards of the new facility in 2021
- Successfully improved the source ability rating from level 4 in Q3 of 2021 to on track for movement into a source ability rating of level 5 in Q3 of 2022, showcasing a proactive approach to enhancing operational efficiency.
Assistant Quality Manager
Magna
Highland Park, MI
09.2015 - 11.2017
- Responsible for the GM and Ford business units overseeing customer scorecard
- Oversee on-time PPAP activity with the customer, appearance reviews, SRV’s and run-at-rates
- Led activity within bullet point read across systems, supported IATF 16949 compliance, built knowledge back with supplier quality, quality engineers, and 7 quality technicians
- Managed business unit key operating indicators driving action plans to sustain or improve overall performance
- Maintained departmental workload to support the success of both business units.
- Mentored and encouraged employees to strive for excellence while fostering professional growth.
- Followed quality standards and procedures to minimize errors and maximize customer satisfaction.
- Provided observations, took measurements, and performed tests at various stages according to quality control plan.
Assistant Quality Engineer
Magna
Novi, MI
06.2013 - 08.2015
- Responsible for supplier and customer program launch preparation, non-saleable, saleable and fully approved PPAP submissions
- Leads the team in prototype development and initial quality documentation development
- Responsible for creation of PFMEA, process flow and control plans
- Leads the team in customer appearance reviews, APQP timing charts, execution to meet customer timing and escalates as needed if any red flags exist
- Experienced in creation of in depth core documents, standardized work instructions & scrap reporting analysis charts
- Leads product development meetings and serves as the key quality contact to the customer base for program launch
- Maintains and updates open issue matrices while assigning job tasks to key APQP members to push issues to closure in a timely and quality manner
- Experienced and knowledgeable with OEM systems; for a tier 1 automotive manufacturer and assembler of seating systems
- Accountable to promote OEM relationships
- Successfully launched the Cadillac ELR program in 2013
- Led suppliers through development and effectiveness of PPAP
- Plans and executes with PM design reviews
- Plans and executes quality gate reviews
- Plans and executes FEMA and CP reviews
- Executes audits and assessments within assigned projects
- Assures project maturity level through escalation and closure of open issues in the project phase
- Creativity, verbal and written communication skills, analytical and problem solving ability
- Experienced with Microsoft office
- Lead PFMEA and CP reviews
- Responsible for customer PPAP’s and support for supplier PPAP submissions.
- Performed quality inspections and drafted reports to detail non-conforming material issues.
Advanced Product Quality Planning/Quality Engineer
Magna Interiors
Howell, MI
06.2011 - 06.2013
- Responsible for supplier and customer program launch preparation, non-saleable, saleable and fully approved PPAP submissions
- Experienced in creation of in depth core documents, standardized work instructions & scrap reporting analysis charts
- Leads design reviews, product development meetings and serves as the key quality contact to the customer base for program launch
- Maintains and updates open issue matrices while assigning job tasks to key APQP members to push issues to closure in a timely and quality manner
- Experienced and knowledgeable with OEM systems; for a tier 1 automotive manufacturer and assembler of interior components with sales of $290,000,000/year
- Accountable to promote OEM relationships
- Successfully launched 3 programs in 2012 exceeding over 110,000 VPY total volume
- Led suppliers through development and effectiveness of PPAP
- Achieved full PPAP approval on 97 finished good door panel part numbers prior to program launch
- Managed supply base exceeding 30 companies and PPAP’ed over 300 part numbers covering all 18 elements of PPAP
- Automotive interiors door uppers, door systems, load floors, overhead consoles and headliners
- Plans and executes with PM design reviews
- Plans and executes of quality gate reviews
- Plans and executes FEMA and CP reviews
- Executes audits and assessments within assigned projects
- Assures project maturity level through escalation and closure of open issues in the project phase
- Creativity, verbal and written communication skills, analytical and problem solving ability
- Experienced with Microsoft office
Quality Engineer/Assistant Business Unit Manager
Magna Interiors
Howell, MI
01.2008 - 06.2022
- Responsible for supplier and customer PPAP submissions
- Experienced and knowledgeable with OEM systems; for a tier 1 automotive manufacturer and assembler of interior components with sales of $270,000,000/year
- Accountable to promote OEM relationships
- Led suppliers through development and effectiveness of PPAP
- Automotive interiors door uppers, door systems, load floors & overhead consoles
- Company turn-around from nearly a $1,000,000 loss per month in 2009 to a 7-figure profit in 2010
- Over $14,000,000 turnaround from 2009 to 2010
- Scrap improvements greater than 50% improvement when compared to 2009
- Reduction of customer dissatisfactions greater than 60% when compared to 2009
- Successful launches in 2008 of LC Challenger interior door uppers
- Control Plan, FEMA and flow development
- Repeat and Reproducibility studies
- Root cause analysis and corrective action development and implementation
- APQP for Lambda MCE business
- Maintain program open issues log
- Warranty
- Capability Studies
- Standardized work instruction development and implementation
- Experience with SPC and GD&T
- Documentation updates – Quality documents, program timing and deliverables
- Program build events and status
- Updated production board documentation (Quality Pyramid, Action Plans, etc.)
- Performed quality inspections and drafted reports to detail non-conforming material issues.
- Contributed to root cause analysis to determine core reason for failures and errors
- Contributed to root cause analysis to determine core reason for failures and errors.
Quality Coordinator
Magna
Howell, MI
06.2006 - 01.2008
- Responsible for supply base, internal and external quality and part gauging
- Recorded findings of inspection process, collaborating with quality team to implement corrective actions.
- Implemented the concept of standardized work by creating work instructions that followed a fast and effective inspection strategy for 6 programs within the facility
- Capability Studies
- Standardized work instruction development and implementation
- Developed monthly, end-of-quarter and other statistical reports for leadership team and quality improvement programs.
- Experience with Statistical Process Control (SPC)
- Layered Process Audits
- Incoming Inspection Audits
- Mistake proof testing
- Immediate and long term corrective action implementation
- Supplier Quality
- Documentation updates – Quality documents
- Updated production board documentation (Quality Pyramid, Action Plans, etc.)
Quality Engineer/Assistant Business Unit Manager
Magna Interiors
Howell, MI
06.2008 - 06.2022
- Responsible for supplier and customer PPAP submissions
- Experienced and knowledgeable with OEM systems; for a tier 1 automotive manufacturer and assembler of interior components with sales of $270,000,000/year
- Accountable to promote OEM relationships
- Led suppliers through development and effectiveness of PPAP
- Automotive interiors door uppers, door systems, load floors & overhead consoles
- Company turn-around from nearly a $1,000,000 loss per month in 2009 to a 7-figure profit in 2010
- Over $14,000,000 turnaround from 2009 to 2010
- Scrap improvements greater than 50% improvement when compared to 2009
- Reduction of customer dissatisfactions greater than 60% when compared to 2009
- Successful launches in 2008 of LC Challenger interior door uppers
- Control Plan, FEMA and flow development
- Repeat and Reproducibility studies
- Root cause analysis and corrective action development and implementation
- APQP for Lambda MCE business
- Maintain program open issues log
- Warranty
- Capability Studies
- Standardized work instruction development and implementation
- Experience with SPC and GD&T
- Documentation updates – Quality documents, program timing and deliverables
- Program build events and status
- Updated production board documentation (Quality Pyramid, Action Plans, etc.)
- Performed quality inspections and drafted reports to detail non-conforming material issues.
- Contributed to root cause analysis to determine core reason for failures and errors
- Contributed to root cause analysis to determine core reason for failures and errors.
Education
Bachelor of Arts - Business Administration
Cleary University
Howell, MI06.2014
Skills
- Analytical mindset
- Corrective Actions
- Internal Auditing
- Continuous Improvement
- Document Management
- Compliance Monitoring
- Customer Satisfaction
- Team Training
Timeline
Senior Advanced Quality Manager
Magna Seating
12.2022 - Current
Quality Manager
Magna
11.2017 - 12.2022
Assistant Quality Manager
Magna
09.2015 - 11.2017
Assistant Quality Engineer
Magna
06.2013 - 08.2015
Advanced Product Quality Planning/Quality Engineer
Magna Interiors
06.2011 - 06.2013
Quality Engineer/Assistant Business Unit Manager
Magna Interiors
06.2008 - 06.2022
Quality Engineer/Assistant Business Unit Manager
Magna Interiors
01.2008 - 06.2022
Quality Coordinator
Magna
06.2006 - 01.2008
Bachelor of Arts - Business Administration
Cleary University