Carl Fusaro
Clayton,NC
Summary
A self-directed Lead Quality Engineer. Expertise in processes such as; electrical-mechanical and fiber optic products. Has the ability to manage multiple projects in parallel, in an efficient and continuous cost improvement manner, while implementing Lean and Six-Sigma Black Belt methods.
Overview
16
16
years of professional experience
1
1
Certification
Work History
Lead Quality Engineer (Fiber Optic Cables)
Leviton
09.2020 - Current
- Lead a scrap reduction Black Belt Project; reduced start-up scrap by over 50% ($275K savings annually).
- Generate team PFMEAs for process improvements.
- Initiate and drive continual improvement with problem solving teams to address internal quality issues and customer complaints.
- Conduct supplier and internal TL-9000/ ISO-9001 audits.
- Participate with external TL-9000 & RI.SE auditors for industry compliance to maintain site certification.
- Manage the QMS system, for documentation control Change Notices and ECRs on the Oracle System.
- Quality support for launching PDI projects. PDI Compass Award recognition for the new Armoring Line.
- Direct all new hire TL-9000 QMS quality trainings.
- Report and present Quarterly DPPM charts to Leviton's corporate management.
- Respond to customer complaints using 8-D tools.
- Produce Quality Notifications for supplier issues.
- Involved with the Global Quality Team Improvement Projects such as standardizing the ICAR (Corrective Action) system.
- Ensure Executive KPIs (Key Process Indicators) are met for Cost-of-Non-Quality, Factory Gross Scrap and On-Time-in-Full.
Supplier Quality Engineer (Electro-Mechanical)
Sensus Corporation
05.2018 - 06.2020
- Drove PPAP’s to completion with suppliers with the NPI phase gates for; Omni, Command Link and Ally Programs (water metering systems).
- Identified Critical to Quality Characteristics (CTQs) for NPI programs.
- Generated CAPA’s (8D methodology) for suppliers' quality issues.
- Participated in PFMEAs to improve product quality
- Lead supplier quality audits to qualify new and current suppliers to meet quality standards.
- Participated in ISO-9001:2015 in external site industry audits.
- Performed internal site audits for ISO-9001.
- Created Temporary Manufacturing Specifications (TMS) to assure proper implementation of NPI parts.
- Provided Quality Control Plans as input to the New Product Development process.
- Collaborated with Manufacturing, Design & Test Engineering to define quality parameters and data analysis and actions.
Quality Engineer (Electronics)
Asteelflash Group
08.2015 - 04.2018
- Managed critical customer quality investigations to contain non-conformances, conduct root cause analysis investigation and drive problems to resolution using 8D/ CAPA methods.
- Directed interface with the customers and other department disciplines for quality issues.
- Performed internal audits for site compliance of quality standards; ISO-9001, ISO-13485 & AS-9100
- Lead daily QRQC (Quick-Response-Quality-Control) meetings to resolve internal and external quality issues with the 8-D problem solving process.
- Generated weekly and monthly quality reports (defects, yield, scrap, etc.) internally and for customers.
- Streamlined the RMA process system for PCBAs.
- Conducted MSAs; an agreement attribute study for inspectors and a GR&R to qualify a new scale for products.
- Implemented and trained the operators for SPC at critical PCBA process stations.
Quality Engineer (Contract)
Honeywell Aerospace
01.2015 - 08.2015
- Generated company quality position papers for customers on critical investigations
- Analyzed and reported customer quality data related to customer returns, score cards and customer quality issues
- Established effective communication to ensure customer issues are resolved and corrective actions deployed consistently
- Communicated with the customers to resolve product quality issues
- Initiated and managed corrective actions in eCATS.
- Greenbelt Team Project for the Engine’s Accessory Power Units (APU)
- Improved and sustained First Pass Yield and On-Time-To-Customer-Request metrics for specific Engine Program APU’s
- Utilized Greenbelt tools such as: Kaizen events, Value stream mapping, process time studies, FMEA, mixed-model board, 5S events, improved test stand layout, and control plans.
- Supported the Electro-Hydraulic Servo-Valve (EHSV) clean room production cell.
Quality Engineer (Automotive)
Sona-BLW Precision Forge
06.2014 - 01.2015
- Key quality customer support and interfacing for side gears and pinion products.
- Responsible for the quality of the forging and packing process.
- Submitted PPAP’s for customers to qualify new parts, processes, tooling and work centers.
- Created and updated inspection instructions for in-process quality product checks.
- Conducted in-process and product manufacturing audits in compliance with TS-16949.
- Project which reduced corrosion on parts from transport.
- Researched and qualified new rust inhibitor.
Supplier Quality Engineer (Contract)
John Deere
08.2010 - 04.2014
- Supported new program part approvals via Production Part Approval Process (PPAP) of commercial mower products.
- Implemented the AIAG Advanced Product Quality Planning (APQP) process for new product introduction and product improvement programs.
- Presented Quality KPI’s to the Product Council.
- Generated PFMEA's, Control Plans, Process Capability studies and GR&Rs.
- Reviewed and approved a high volume of part commodities such as; sheet metal, castings, pulleys, electrical components, harnesses, hydraulic pumps, fuel tanks, transmissions and engines.
- Performed manufacturability reviews covering engineering tolerances, and specifications.
- Participated in Design Process and Assembly Reviews (DPAR's) with suppliers and the project team to determine the QPL requirements of the parts.
Quality Engineer (Automotive)
GKN Driveline
05.2008 - 06.2010
- Responsible for reduction of internal scrap and customer DPPM defects.
- Conducted quality improvement projects leading to scrap reduction for part run-out, flashing and rust reduction.
- Coordinated the quality Improvement activities for root cause analysis and corrective actions of customer complaints.
- Implemented SPC on critical features of the product for scrap reduction.
- Accountable for safe launch & submitting PPAPs, via APQP.
- Participated in internal audits to meet the TS-16949 Certification Standards.
- Designed tooling and gauges for first article inspections.
- Participated in team Kaizen events for flow lines improvements; created a flow lane buffer management system.
Education
Bachelors of Science Degree in Physics -
State University of New York at Stony Brook
Masters of Science Degree in Education -
New York Institute of Technology At Old Westbury
Skills
- Lean Six Sigma Black Belt Methodologies
- Engineering Project Leadership
- Quality Cost Reduction Projects
- Process Improvement Projects
- 8-D Problem Solving
- Auditing (TL-9000 & ISO-9001)
- PFMEAs
- PPAP & APQP
- Mini-Tab & JMP Statistical Software
Certification
- Lean Six Sigma Black Belt Belt, Emory University, August 2023
- Engineering Leadership Certificate (6 Courses), Cornell University, May 2024
- Six Sigma Core Green Belt Certified, Honeywell Aerospace
- ISO-9001: 2015 Internal Auditor Certification, N.C. State University
- FMEA Certification, Automotive Industry Action Group
- APQP & PPAP Certification, N.C. State University
- IPC-610 Acceptability of Electronic Assemblies Certification, Sensus Corp.
- Toyota Production System Certification, GKN
- Cause Analysis & Mistake Proofing Workshop, Honeywell Aerospace
Manufacturing Engineering Experience
Manufacturing Engineer (Aerospace); BAE Systems, N.Y.
Support engineer for the Wedgetail & Peace Eagle programs. Team involvement for all program phases. Managed engineering processes such as; wave soldering, screen-printing, assembly cleaning, conformal coating and surface-mount placement. Improvements of manufacturing methods; reduction of workflow process time, equipment selection and design of custom tools.
Timeline
Lead Quality Engineer (Fiber Optic Cables)
Leviton
09.2020 - Current
Supplier Quality Engineer (Electro-Mechanical)
Sensus Corporation
05.2018 - 06.2020
Quality Engineer (Electronics)
Asteelflash Group
08.2015 - 04.2018
Quality Engineer (Contract)
Honeywell Aerospace
01.2015 - 08.2015
Quality Engineer (Automotive)
Sona-BLW Precision Forge
06.2014 - 01.2015
Supplier Quality Engineer (Contract)
John Deere
08.2010 - 04.2014
Quality Engineer (Automotive)
GKN Driveline
05.2008 - 06.2010
Bachelors of Science Degree in Physics -
State University of New York at Stony Brook
Masters of Science Degree in Education -
New York Institute of Technology At Old Westbury
- Lean Six Sigma Black Belt Belt, Emory University, August 2023
- Engineering Leadership Certificate (6 Courses), Cornell University, May 2024
- Six Sigma Core Green Belt Certified, Honeywell Aerospace
- ISO-9001: 2015 Internal Auditor Certification, N.C. State University
- FMEA Certification, Automotive Industry Action Group
- APQP & PPAP Certification, N.C. State University
- IPC-610 Acceptability of Electronic Assemblies Certification, Sensus Corp.
- Toyota Production System Certification, GKN
- Cause Analysis & Mistake Proofing Workshop, Honeywell Aerospace
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