DAVID M VILLWOCK
Textron Systems
Baltimore,MD
1
Certification
33
years of professional experience
Results-driven Quality Manager and Principal Quality Engineer with expertise in managing aerospace, defense, and automotive projects from design to launch. Skilled in APQP, PPAP/FAI processes, and developing Quality Plans. Leverages Lean Six Sigma Black Belt methodologies for continuous improvement and effective engineering change control.
Work History
Quality Engineer IV
5 Years 9 Months- Led introduction of new product into facility with strict quality requirements such as lot traceability, analysis of prohibited substances, statistical process control, 100% inspection data requirements, special process approvals and supplier management, and usage within 5 years of date of manufacture.
- Monitored resource levels in the department and coordinated quality efforts for upcoming proposals.
- Trained and mentored new quality engineers in managing quality systems.
- Led external customer audits of special processes (welding and paint) for ASPL inclusion and participated in AS9100 certification audits.
- Subject Matter Expert on the First Article Process. Led training efforts and supported other Quality Engineer efforts to complete FAIs.
Quality Program Engineer
2 Years 3 Months- Introduced PFMEA’s using families of common sub assemblies that were viewed by customer as a best practice and they requested to use them across their network of suppliers to develop their processes.
- Created First Articles and handled Source Inspections for launch of new products for new private aircraft.
- Managed Last Article Inspection reports to ensure compliance with quality standards. for outsourcing of product and training of customer expectations.
- Completed training and achieved certification for issuance of 8130-3 forms.
Quality Manager
2 Years 9 Months- Took over during the launch of (2) F150 Frame assembly lines filled and managed staffing needs, developed process monitoring and inspection procedures, job instructions, control plans/PFMEA’s, disposition process, and completed the difficult PPAP process due to existing Assembly Equipment and Components versus Tower designed and built parts.
- Addressed daily quality issues to ensure product standards. and the reduction of rejects (QR’s) at the customer including developing 8D’s and follow thru on Corrective Action thru team methodology.
- Reduced 3rd party involvement in Safe Launch activities during ongoing assembly line launches and engineering changes for new models (Raptor and Diesel).
- Guided plant through two TS 19649 certification audits to ensure compliance. and managed transition from TS to IATF19649 with only one minor non-conformance.
- Certified Ford Capacity Planner completing all GCP study analysis and Phase 0 activities.
- Created metrics to monitor improvements in rework and scrap activities.
Program Manager/Industrial Engineer
17 Years 7 Months- Developed and managed an internal engineering change system to communicate details of changes to operations, materials, finance, quality, engineering, purchasing, and commercial groups through monthly presentations.
- Responsible for the Ford Econoline and Ranger Frame lines including stamping dies and welded assembly process.
- Liaison with Ford Engineering and Purchasing for the product changes required over fourteen model years changes consisting of over $14M in change to new and existing tools. All changes completed on time and under budget using APQP process.
- Responsible for the transfer, install and launch of thirteen manual spot weld assembly cells and part stamping dies for AM-General MV-1 program, on time and with zero interruption of product supply. Evaluate, quote and implement design changes of over $2M to meet new regulations.
- Collaborated with suppliers and tool shops to refurbish stamping dies and assembly tooling over twenty years old, ensuring uninterrupted production and addressing unforeseen issues that arose during the die work.
- Certified Tower Lean Six Sigma Black Belt.
- Completed four weeks of class study, Ergonomic Workshop, hosted a week long Lean Workshop in Auburn, IN plant and passed Certification Test.
- Used data collection and capability analysis, hypothesis testing, DOE experiments and Lean workshops to complete project and make improvements in the plant.
- Improved label adhesion through process from 56% to 96%.
- Reduced ecoat paint cycle time by 25% and Voltage by 37%.
- Eliminated scrap from part fit up issues causing bad welds.
- Optimized ECoat zinc phosphate maintenance through DOE.
- Reduced rivet rework by modifying the shape of the finished B-Head to improve material flow during the squeezing process.
- Worked with the Quality and Operations groups to make design modifications to parts and adjustments to Assembly and Stamping Tools, and worked with customer for dimensional concessions.
- Led the evaluation and quoting of new business opportunities in Bellevue facility including the transfer of existing equipment into the facility, filling up available capacity in our ecoat system and open floor space.
- Led Continuous Improvement projects to automate a manual station and move parts throughout the line to rebalance time and redeploy employees and save extra repair at Ford.
- Developed layout process and worked with contractors on implementation of assembly equipment for start-up of DEW98 Plant and completed Labor studies, work instructions, print control, PFMEA/Control Plans.
Industrial Engineer
3 Years 2 Months- Designed layout for the entire 450,000 sq ft plant, including the setup of two new additions.
- Led Continuous Improvement Teams to implement lean manufacturing principles with hourly employees. with hourly employees from plant floor to implement synchronous and lean manufacturing concepts resulting in improvement in quality and process flow and reduction in WIP inventory and implementation of Kanban system that was managed by hourly employees in Work Cell.
- Implemented overhead conveyor system to enhance material flow and increase productivity. and productivity improvements by installing overhead conveyor system to feed plant.
- Set up work cells based on time and motion studies, standard data, operating procedures, process FMEAs, and process flows for new products entering the plant.
- Managed daily operations addressing manpower and production challenges on plant floor. dealing with manpower issues, production problems, and process improvements on the plant floor. Improvement is tracked by using SPC and p-charts.
- Organized paint line rework flow and reduced paint line scrap. Managed packing and labeling designs and procedures.
- Maintained routings and assisted in constructing bills of materials.
- Worked in the scheduling department to install pull systems on the floor.
- Performed and managed capacity studies and throughput analysis for plant productivity.
- Executed packaging engineering tasks including testing and modifying racks for efficiency. from testing, tracking and modification of racks.
Industrial Engineer at GM-Inland Fisher Guide
1 Year 9 Months- Built computer simulation models to balance line flow, implement synchronous environment, and prevent incorrect changes, resulting in reduced labor costs.
- Conducted time studies and utilized standard data to enhance productivity in joint union/GM workshops.
- Supervised daily operations on plant floor, ensuring efficient workflow and safety compliance.
- Served as process and tooling engineer in start-up of new product in plant.
Education
B.S. Degree - Industrial & Systems Engineering
- Graduated Cum Laude [Top 10%]
- GPA: Cumulative G.P.A. 3.6, G.P.A. in Major 3.9
Skills
PPAP and First Article Inspection Process
Root cause analysis
Root Cause Corrective Action - 8D and 5 Whys for Continuous Improvement
Quality Plans
Quality Assurance Documents and Inspection Plans
Statistical Process Control
Non-conforming product tracking and improvement
AS9100/AS9102 and IATF19649 Auditing
Supplier Management and Process Improvement
Lean Six Sigma Black Belt Certification from Tower Automotive
Quality Project Management and Time Management
Computer Skills - Microsoft Office
CAD Viewers
Document Control (JIRA
COLTS
ARMS
SOLUMINA
MATRIX)
Minitab
Training/Mentoring
Certification
Lean Six Sigma Black Belt, Tower Automotive, 2012
Timeline
Quality Engineer IV
Textron Systems
11.2020 - CurrentRead More
Quality Program Engineer
Safran Cabin
07.2018 - 10.2020Read More
Quality Manager
Tower International
10.2015 - 07.2018Read More
Program Manager/Industrial Engineer
Tower International
03.1998 - 10.2015Read More
Industrial Engineer
Venture Industries (formerly Autostyle Plastics)
01.1995 - 03.1998Read More
Industrial Engineer at GM-Inland Fisher Guide
EDS
03.1993 - 12.1994Read More
The Ohio State University
B.S. Degree from Industrial & Systems Engineering
Read More
RECOGNITION
Co-Op at Mead Data Central in Dayton, OH., Awarded 1st place on the 1993 Institute of Industrial Engineers National Technical Writing and Presentation Contest: Worked at Sears Customer Distribution Center in Columbus, OH. Dealt with ergonomic, human factors, and mechanical issues to reduce cost within the facility by improving flow and accuracy of product flow on the conveyor picking system.
Awards
Awards 1st Place in the 1993 Institute of Industrial Engineers National Technical Writing and Presentation Contest. Worked at Sears Customer Distribution Center in Columbus, OH. Dealt with ergonomic, human factors, and mechanical issues within the facility by improving flow and accuracy of product flow on the conveyor picking system.