Daniele Lewis

• Established Material Review Board process, to include analysis of production scrap, and rework. This resulted in cost savings, inventory accuracy, and process improvements
• Established process for identifying scrap and rework per IATF requirements, within operations and checking hourly with cause and improvement actions
• Initiated 5s and flow for Quality non-conforming area to properly identify and control product in and out
• Ensured standard work processes are available for operations and are approved by customer where needed
• Effectively addressed customer concerns promptly. Ensured customer required formats were used for all formal customer complaints. Used industry expertise, customer service skills and analytical nature to resolve customer concerns and promote loyalty. Maintained positive customer relations by addressing problems head-on and implementing successful corrective actions
• Customer Portal administration, to include APQP, SPPS, Warranty processing and analysis of all issues and costing
• Built Managed and directed Production Quality Department. Recruited, interviewed and hired employees and implemented mentoring program to promote positive feedback and engagement
• Guided department to success by defining clear targets, aims and goals for each team member. Reviewed weekly through 1-1 meetings, monthly as team and quarterly as formal employee reviews
• Monitored completion of tasks and ensure reliable performance for both internal and external customers. Maintaining adequate manufacturing and customer support coverage
• Enforced safety procedures and policies throughout manufacturing process. OSHA 10 certified
• Worked positively with support functions to fully define processes/procedures/controls relevant to cross functional team activities. Providing support with customer, product and process expertise and input to continuous improvement activities within team
• Cultivated positive rapport with fellow team members to boost company morale and promote employee retention
• Aided in organizing and overseeing assignments to drive operational excellence.

• Managed Manufacturing floor consisting of Supervisors, Team Leaders, Manufacturing team members and material handlers in union facility
• Supervised production team, keeping production schedules on track to meet tight deadlines
• Maximized performance by watching daily activities and mentoring team members
• Applied lean principles to improve workflow and quality and reduce waste
• Evaluated suppliers to support cost controls and improve operations
• Reviewed processing schedules and production orders concerning inventory requirements, staffing requirements, work procedures and duty assignments, considering budgetary limitations and time constraints
• Conducted performance reviews, offering praise and recommendations for improvement
• Minimized resource and time losses by addressing employee or production issue directly and implementing prompt solutions
• Revitalized operational structures and procedures to successfully control turnover and waste, enhance output, and boost overall quality
• Implemented process improvement to shape organizational culture, optimize procedures for higher efficiency and help company evolve and grow
• Introduced new methods, practices, and systems to reduce turnaround time
• Wrote process, employee and production schedules
• Motivated employees through unique events, incentive programs, and constructive feedback
• Facilitated onboarding sessions and on-the-job training for new hires, bolstering employee job position knowledge and skillset
• Implemented performance reviews and motivational strategies to elevate team results
• Evaluated employee onboarding programs and presented strategic improvement recommendations to upper management
• Used technologically relevant digital systems to manage payroll
• Coordinated employee grievances and disputes in prompt and professional manner by finding constructive solutions
• Updated training processes by reviewing existing documentation, using feedback from associates and working with cross functional teams
• Distributed employee engagement surveys to show areas of improvement
• Created and implemented forward-thinking initiatives to improve employee engagement
• Evaluated employee skills and knowledge regularly, training, and mentoring individuals with lagging skills
• Resolved staff member conflicts, actively listening to concerns and finding appropriate middle ground
• Accomplished multiple tasks within established periods
• Cross-trained existing employees to maximize team agility and performance
• Aided in organizing and overseeing assignments to drive operational excellence
• Maintained positive customer relations by addressing problems head-on and implementing successful corrective actions.

• Performed quality control audits on pre-production supply chain, verifying continuity of raw materials
• Reviewed and validated quality requirements for manufacturing planning, supplier purchase orders, and engineering specifications to meet contract compliance regulations
• Determined root cause of deviations and non-conforming results and implemented proper corrective and preventive actions throughout product development process
• Inspected raw materials and finished products to verify quality and disposed items that did not meet safety requirements
• Used statistical process control (SPC) methods to detect and analyze manufacturing process data and apply process changes
• Designed and performed product audits to verify quality control parameters were kept across multiple production runs
• Directed technical and administrative staff involved in quality control tasks
• Established key performance metrics and detailed corrective scenarios for failures
• Developed and audited practices, programs, and reporting system metrics for optimal efficiency
• Applied lean manufacturing practices to quality control tasks, minimizing waste caused by Mold and Cut processes
• Prepared reports on recorded performance metrics of COPQ, highlighting unacceptable deviations
• Designed training curricula for quality control personnel, instructing employees on factors such as safety, launch and requirements
• Supported quality team members during corrective action updates
• Contributed to root cause analysis to decide core reason for failures and errors
• Performed quality inspections and drafted reports to detail non-conforming material issues
• Coordinated with quality control staff to complete inspections
• Researched and evaluated new techniques and technologies to improve product quality
• Facilitated process improvements to successfully decrease errors
• Executed operational audits and assessed company operations, compliance and other associated risks
• Reported on non-compliance issues and other negative factors discovered during production
• Partnered with senior management to analyze issues and find proper solutions
• Maintained compliance with industry standards and regulatory compliance during managed projects
• Led problem-solving activities to quickly show and permanently resolve quality and productivity issues
• Escalated concerns about project and process quality, referring discovered issues to engineering manager for correction
• Developed action plan for company certification using IATF 16949 standard knowledge
• Recommended revisions to internal controls and operational and management policies and procedures
• Developed traceability documentation to aid in investigating faults and defects.

• Launched Critical to Quality audits
• Lowered scrap cost by implementing creative ways to protect parts
• Promoted and streamlined incentive program for operators finding supplier defects
• Deep dive appearance issues and revised process for operations
• Launched and maintained in station communication screens
• Gather and interpret data from end of line defect collections for daily report out
• Gather and report on audit findings
• Weekly reporting of supplier defect findings and present awards to operators
• Daily reporting of open quality issues
• Deep dive and correct production issues
• Draw cross functional team together for continuous improvement projects
• Write supplier complaints for findings received
• Answer customer complaints with deep dive and corrective actions
• Maintain in station communication presentations with current job training and quality focus.

• Generated quality control reports for returned products to show and communicate patterns
• Supported audit preparation through research, analysis and presentation development
• Assessed quality of finished products with careful inspections
• Collaborated with managers to write procedures for Production, Quality and Sales departments
• Launch BIQ tracking along with introducing corrective action folders
• Developed process auditing documentation based on corrective action needs
• Recovered $68,000 in missed billings
• Developed process for billing reworks
• Developed tracking for internal reworks and cost of inferior quality
• Aided in rewriting work instructions for operations and creating manuals
• APQP for new parts verifying all information is gathered and properly uploaded into Plex
• Transfer shipping requirement layouts to excel form from CAD for operator use
• Generate production reports and send out to operations manager
• Enter all feed forward information sent in from mill into Plex system
• Maintain mill communication for all non-conforming material
• Enter all dispositions of non-conforming material into Plex system
• Build and maintain active record of all reworks and timing of completion
• Maintain shipping requirement updates as turned in
• Issue scrap credit and keep scrap account reconciliation records
• Monthly billing for mill fault reworks
• Weekly billing for mill sample collection
• Helped with customer complaint investigations to improve quality and production processes
• Managed filing system entered data and completed other clerical tasks
• Organized logistics and materials for each meeting and took detailed notes for later dissemination to key stakeholders
• Increased office participation in unique events by creating newsletter with detailed calendars and other office updates
• Interacted with vendors, contractors and professional services personnel to receive orders, direct activities, and communicate instructions
• Surpassed team goals by partnering with colleagues to implement best practices and protocols.

Launch (pre-production) activities

• Quality Coordinator for launch of Alpha IP/OHS Assembly lines
• Provided support to production and advanced team in problem solving activities for all phases of launch
• Provided build support during all manual, non-saleable and saleable build events
• Current production activities
• Complete gauging for all production assembly
• Monitor data, create reports and present opportunities to customer
• Facilitate updates to gauges per customer driven initiatives
• Analyze daily data for completed key process characteristics, torque checks, problem solving activities, scrap review and ongoing first-time quality performance
• Analyze weekly data and prioritize proper and necessary preventive and corrective actions based on analysis
• Support in ISO/TS16949 audit of Holt and Lansing facilities
• Direct customer relations as GM supplier at multiple GM facilities
• Develop and keep communication and support for VAA supplier concerns with on-site GM support staff
• Awarded for successful completion of streamlining processes and eliminating need for three operations
• Leader in root cause analysis and problem-solving initiatives
• Leader in corrective action planning and implementation
• Started and kept layered process audit system in Lansing 2 facility
• Analyze weekly data and prioritize proper and necessary preventive and corrective actions based on analysis
• Report findings and resolutions to team and upper management
• Managed engineering change coordination
• Interim activities - Acting Quality Engineer
• Maintenance of document business system for Holt facility
• Maintain core documents, PFD, PFMEA and Control Plan for IP system
• Achieved timing on all document milestones for control document completion
• Production process engineering includes launch of new product lines
• Responsible for daily presentation of quality issues at fast response meeting
• Answered all formal customer complaints completely within 24-hour return time window
• Responsible for daily tracking of customer concerns and open issues
• Lead in production complication / failure resolution
• Oversee all repairs and bypass operations
• Incoming Quality Control
• Oversaw daily maintenance of supplier quality
• Responsible for initiation, completion and follow-up of supplier non-conformance reporting
• Designed and implemented repair processes for internal defects caused by production
• Launched new production shift as quality support
• Functioned as liaison between plant and GM on quality rejections acting solely responsible for determining breakpoints, initiating quality alerts and communication of customer response in accordance with company and customer policies for second shift
• Awarded for successfully finding processes affecting part quality and providing alternative process controls
• Managed all quality initiatives taking place on second shift
• Supervisor of sorting and corrective action implementations from suppliers
• Production associate / Team leader
• Lead team of 35 operators while maintaining production / quality standards for department supplying 3 product lines
• Analyzed existing processes for assembly and lead team for streamlining and efficiency improvements
• Lead trainer for new hires and transfers into department.