GREGORY LEVERETTE

A highly successful proven Supplier Quality Manager, Quality Manager, Sr. Lean Six Sigma Manager with over (25) years of diversified engineering experience in Quality, Reliability, Operation, Manufacturing, Engineering Management, Sr. Lean Six Sigma Engineer, Reliability, Process and completing Continuous Improvement Projects in the Medical and Automotive Industry. Specialist in developing suppliers in PPAP, APQP, PSO, Reliability Testing & Studies, IATF- 16949, ISO 9001, ISO 14001and ISO 13485. I have led launch teams for current & advanced supplier quality that include products such as EV-Battery, infotainment and controls, body system, interior, exterior, trim, casting, chassis, electronics, injection molding, stamping, and electrical modules systems. I have developed risk assessment, feasibility studies, process readiness programs, and key deliverables for advanced quality planning for numerous products. Under my leadership, I have championed and led cross functional problem-solving teams that include APQP and Current Supplier Quality Engineers. As a Master Six Sigma & Lean SS Black Belt, I have completed numerous continuous improvement projects. My goal is to direct business leaders, maximize profits for Safety, Quality, Delivery, Cost, Morale, Inventory, Purchasing, Productivity, Customer Service and Environment utilizing KPI & KAI. I have implemented and developed training classes for Lean Six Sigma White Belt, Yellow Belt, Green Belt, Black Belt and DMAIC certification Methodologies. I have developed procedure, standards, work instruction, policies for Kaizen Events, Kaizen Blitz, Value Stream Mapping processes for company. Throughout my (15) years Engineering Management experience in my career, I have utilized problem solving tools such as DMAIC, Design for Six Sigma, 8D, Shainin Red- X, 5-Why’s, DVP&R, Lean Study, Kaizen, Value Stream Mapping, and Lean Six Sigma approaches for Continuous Improvement. Hardworking employee with customer service, multitasking, and time management abilities. Devoted to giving every customer a positive and memorable experience. Systematic Quality Assurance Manager with an excellent eye for detail and a knack for devising and establishing effective quality procedures, standards and specifications. Talented at clearly specifying quality requirements with suppliers and monitoring procedure performance. Organized quality assurance manager with several years of managerial experience dedicated to detail-oriented production inspections and collaborating with various departments. Proficient in daily product sampling and performing accurate audits. Customer-focused Quality Assurance Manager with many years of experience in industry. Successful at internal audits and correctly forecasting product markets for accurate supplying. Skilled at working with customers and clients to ensure fantastic service. Highly-motivated employee with desire to take on new challenges. Strong work ethic, adaptability, and exceptional interpersonal skills. Adept at working effectively unsupervised and quickly mastering new skills.

• Minitab, 9-30-11
• Master in Six Sigma Statistic, 3-8-13
• Reliability Engineering, 2-25-13
• FMEA, 3-19-13
• Six Sigma Champion Belt, 9-21-12
• Master Implementer Six Sigma, 8-11-12
• Master Six Sigma Black Belt, 11-25-12
• Six Sigma (DFSS) Course
• Six Sigma (Black Belt) training, 4-17-10
• Master (Black Belt) training, 8-11-10
• SYSTEM APPROACH TO QUALITY IMPROVEMENT
• Certified Quality Engineering Training
• ISO/QS 9000 Certified Lead Quality Auditor
• Certified Reliability Engineering Training

Recipient of the Angileri Quality Award by Frank E. & Bessie Angileri for Quality Improvement in the Automotive Industry during the Master's degree program at Madonna University in 1999.

• Ronin Staffing, LLC, Glendale, CA, STA- Resident & Warranty Engineer, 10/2/23 to Present, Spearheaded resolution of STA-BSAQ issues, conducting root cause analysis and implementing corrective actions, resulting in a 15% improvement in supplier quality performance., Implemented quality improvement initiatives resulting in a 20% decrease in STA-Electrical Module warranty claims., Collaborated with cross-functional teams to address White Board issues for MAP, contributing to a 10% reduction in defect rates., Assist VRT team with the White Board issues, for (MAP), and work with PVT team for closure on all issues., Assist (IQ) Dept with all STA-Electrical Modules -Stop/Ship -containment and drive back to supplier for resolution and request detailed 8D’s for closure., Help support (Bronco/Ranger) launches for STA- Modules Electrical issues for ECG, PCM, ACM, GWM, CIM, CGW, TCU, Display Screen, and other Modules for Root Cause analysis of Quality Issues., Assist Electrical Module supplier with QR, PPM, Paynter Chart, to help them drive Quality performance improvement with Supplier., Lead and manage all STA-Electrical Module warranty claims, for Suppliers in the BSAQ binning meeting, to get resolution for all issues., Help- PVT-team to Root Cause all process BSAQ -issues in the plant, conduct process walk, to come up with resolution for the process issues with Electrical Modules., Lead focus engagement supplier in their Warranty for (-1MIS, 0MIS, and 3MIS) for Quality Improvement, and help them set up their Paynter charts, to drive resolution of all their Quality defects., Support and Drive -STA-Supplier dispute issues for CR/QR and Warranty claims, drive to resolution with the 8D’s process., Help-Electrical Module Supplier, to develop a robust Quality System, by reviewing their PFMEA, Control Plan, Gage R&R, SPC-PpK and Pp for the Quality defects and resolution., Lead and Drive Supplier leadership team to achieve all of Ford Focus Supplier target of (20 to 30) % Quality Improvement for CR, QR, Warranty, Stop/Ship for the Electrical Module supplier., Conduct onsite review with Focus engagement supplier to review Health Charts, Paynter Charts, Review Manufacturing Process, Corrective Action Process, and their 8D’s .
• LMC, Farmington, MI, Supplier Quality Engineering Manager, 3/15/21 to 9/1/23, Lead and manage APQP, PPAP, PSW, Reliability Testing and Studies, for EV-Battery, Electrical Module, Components, BMS, Infotainment and Controls on the EV-Endurance pickup truck., Led Launch Quality team development plan & process readiness plans for EV-Battery, Infotainment & Control Suppliers, Evaluated –First Article Inspection part, for there test plan, inspection plan, GD&T-print, to verify that the (6) parts meet all of the Customer requirements., Directed APQP, PPAP, and Reliability Testing processes for EV-Battery and Infotainment suppliers, ensuring on-time launches and compliance with quality standards., Successfully managed supplier quality reflash activities, resulting in a 30% reduction in defective electronic components., Developed and implemented Supplier Scorecards, leading to a 25% improvement in supplier performance metrics., Work with Supplier and Manage the Supplier in developing Reliability DVP&R, Hass testing, Weibull testing, Durability testing, accelerate life testing, BMS testing for based on Failure mode with components., Develop FMEA, for all Reliability Product Design test failure modes, for System, Components, assembly, and some manufacturing processes., Project Management – of all Electrical Supplier for Modules and Wire Harness for Quality Improvement., We conducted reliability testing with supplier on High Voltage lines, Relay switches, Low Voltage lines, Battery Cells, High Voltage Modules, and Infotainment Modules, CIM, BCM, ACM, Modules for Stress testing, Validation, an Environmental testing,, We conducted Reliability studies with the Supplier based on Weibull to predict the Failure rate, on Battery systems, BMS –components, Battery pack, and modules., We conduct Reliability testing to be able to fine latent Failure modes with the Battery Management Systems, with testing for Temperature, Vibration, Environment, Stress, Durability testing of the products., Developing a Supplier Scorecards with team to ensure supplier compliance and driving supplier performance improvement plans for Infotainment & Controls, Develop a (6) documents (Buy -Off) process list for PPV readiness for Suppliers., Support SQE- in training, coaching on PPAP, APQP and Buy -Off process for PPV., Work with Engineering team on developing, Deviation, Problem Solving, and Engineering Issue, Train and Develop Suppliers, using PFMEA, DFMEA, Control Plan, Gage R&R, SPC, MSA, GD&T -prints, DIM Study and completing their PSW’s, Interim Non- Saleable PPAP, and Buy -Off process for PPV, Supplier deck cover, Infotainment and Control Suppliers and Body, Electrical, Trim, Exterior, Interior, Safe, Stamping, Injection Molding, Chassis, and casting Part Suppliers, Work with Purchasing on solving commercial Issues, with PO, Timing, and SOR issues., Work with Engineering team on developing reflash – process for TCU -Modules, CIM and CGW, Mitigate risk my tracking all the KAI & KPI for the Infotainment and Control Suppliers
• DMS, Detroit, MI, Supplier Quality Engineering Supervisor, 4/13/20 to 2/15/21, Train, Motivate, develop APQP & Current SQE in Control Plan, FMEA, PFMEA, Control Plan, GD & T, MSA, dimensional study, Gage R & R, SPC, 8D, and other problem-solving tools., PPAP, all the injection molding parts for trim, for the Ford F-150- IP, the parts that we manufactured at our plant., Supported approval of CN and PPAP processes, ensuring compliance with customer requirements., Led the Launch Quality team for Ford F150 IP Panel, achieving PPAP approval ahead of schedule., Managed a team of 12 APQP & Current SQE engineers, providing leadership and guidance to ensure timely completion of deliverables., Complete SQE performance that includes APQP document reviews and provides feedback for continuous improvement., Develop Suppliers by utilizing six sigma tools such as DMAIC for solving Advance Quality Planning, launch problems, and process readiness problems., PPAP- the Hvac system in the Ford F-150 in the IP, Sensors, Vents, Hvac housing, Injection Molding, Exterior Components, and controller devices for the suppliers., Support supplier quality engineers including coaching, feedback, and motivation, assuring that the team/department is operating at the highest efficiency., Developing Supplier Scorecards with team to ensure supplier compliance and driving supplier performance improvement plans., Build and manage SQE team members to improve their capability to meet the business and team growth requirements., Manage all supplier quality reflash for major electronic components, such as ECG, sync, ECM, clusters, CIM, TCU, CGW, Dual display, and ICS modules and Ford Health Charts, Paynter Charts, for their 8D’s., Manage DMS electrical deck that includes 8 suppliers and oversee all SQEs deck., Implement cost recovery based on supplier chargebacks for defective product shipped to DMS & DTP., Manage SQE to support approval of CN and PPAP., Manage supplier issues from root cause to permanent corrective action by communicating and initiating corrective and preventive action requests to suppliers., Ensure timely response from suppliers to ensure effectiveness of 8D that tackles root cause, eliminates reoccurrence, and maintain a Master Supplier Matrix for launch., Monitor the status of quality hold cage for defective parts, establish RMA for cost recovery of all defective parts.
• EO-Tech and L3 Company, Ann Arbor, MI, Sr. Advance Supplier Quality Engineer Management, 5/15/17 to 3/20/20, Managing and Champion problem solving with PPAP and APQP and conducting process review of the PPAP and Supervised over (6) -SQE-engineers, Requested (A3-problem solving problem) from each of the supplier for NC-condition with their parts, that do not meet our customer requirements., Lead EO-Tech and Supplier team in the development, Supplier Validated Special Process List, Process Flow Diagram, Production Process approval Requirements, Process Control Plan, Inspection Plan, PFMEA, Review DFMEA, Master Validation List, PFD Final, FAI, Gage R&R, CpK –studies, C of C, Material Certification, PPAP Warrant, and PPAP check list., Conduct Quality System Audit on process for ISO/TS 16949 Audits in the plant., I conducted Continuous Improvement projects with the supplier on multiple problem-solving projects for the scope sights.
• Zimmer Biomet Inc., Warsaw, IN, Sr. Advance Supplier Quality Engineer Consulting, 8/15/16 to 4/28/17, Managing and Champion problem solving with SPPA, PPAP+, and APQP, conducting all (4) phase of the PPAP+ processes., Evaluated –First Article Inspection part, for there test plan, inspection plan, GD&T-print, to verify that the (6) parts meet all the Customer requirements for the medical industry., Help-Medical component Supplier, to develop a robust Quality System, by reviewing their PFMEA, Control Plan, Gage R&R, SPC-PpK and Pp for the Quality defects and resolution
• Emerald Global Consulting Inc., West Bloomfield, MI, Sr. Advance Supplier Quality Engineer Consulting, 1/4/16 to 6-28-16, Managing and Champion problem solving with Ford, GM, Fiat Chrysler, to Root Cause Analysis using Six Sigma, Methodologies DMAIC, DFSS, MSA Studies, Shainin Red X, 8D, and problem-solving tools., Trained (Supplier –Magna) on the (8) waste conditions needed to be removed out of their processes, based on Multiple Product line that resulted on $500K improvements. Lead Magna and Supplier team in the development of PPAP, APQP, PSO, VDA 6.3, Lean Kaizen, VSM, Quality Scorecard, and lessons learned reports. PPAP over (300) supplier at Magna.
• Jabil, Auburn Hills, MI, Plant Lean Six Sigma Manager, 6/8/15 to 6/1/16, Managing and Champion of continuous improvement for Lean for the VSM – mapping of all product line. I Manage (4) Six Sigma Black Belts and their Projects., Coach-Lean and Six Sigma candidates on completion of their Lean Bronze Certification, VSM –Baseline, Current State, and Future State VSM for their product lines., Supervised and conducted Lean Bronze exam-for Engineers, Managers, and reviewed Lean Six Sigma Projects Charter, CAPA, DMAIC and DMADV projects and sign-off for approval.
• Navistar, Lisle, IL, WorkStar Reliability & Quality Platform Manager, 11/1/2014 to 5/28/15, Managed and supervised over (16)- Reliability, Black Belt, and Quality engineers, I have Lead Reliability team in the development of Halt/Hass Accelerated life testing, Accelerated Weathering testing, DVP&R testing Plan, Stress Testing, Durability Testing, MTBF & MTTF, Testing, Failure Mode testing, on motor vehicles and components., Complete components on Hvac systems, DFMEA and PFMEA, based on Failure modes in DVP&R, and Reliability testing, for Compressor, Condenser and heater core., Root Cause, manufacturing leaks in the manufacturing process systems with Leaks in the condenser and heater core, by using the 8D problem solving tool., Set up APQP and Completed PPAP on the Hvac system with the suppliers, for Condenser, Compressor, Evaporator core, Sensor, Controllers and orifice tubes., Work with supplier, the complete testing and DVP&R testing on the top & bottom plastic parts on the condenser and radiators for the Climate Control Systems,, Lead WordStar team in the development of warranty 3MIS, 12MIS, CPU, Quality Scorecard, and lessons learned reports, Led more than (15) projects with a team using, DMAIC, DMADV, DFSS, Shainin Red X, and using Six Sigma Methodologies that had Quality Lean improvement of 30% that resulted in over $3.4M in saving., Interface with all WorkStar customers based on new Launch program for WorkStar Platform, launch readiness, APQP, PPAP and Design Review., Set target goals for CPU,3MIS, 12MIS Quality Improvement, for MY-2015, MY 2016, and MY 2017 year for WordStar Platform
• Navistar, Lisle, IL, Sr. Master Black Belt Reliability Engineer II, 11/1/2012 to 11/1/14, Developed Navistar Six Sigma White Belt, Yellow Belt, Green Belt, and Champion Belt Program at Navistar., Conducted a (5S) program for each of the Navistar (6) plants that resulted in 33% improvement for over $ 900K in cost avoided in saving., Managing and supervising a team (9 students) of Six Sigma Greenbelts and Black belts students through internal and external Belt Certification program.
• Navistar, Lisle, IL, Sr. Master. Reliability Engineer 1, 3/15/2010 to 10/31/12, Conduct root because analysis on TMV valve @ Mexico plant based on high warranty issues, provided engineering recommendation for new design and manufacturing improvements., Conduct root cause analysis on (750 lb. Block) -$1M a month lose, 15 Liter Block Engine @ Indianapolis Plant, performed DOE analysis for a porosity problems by identifying critical factors for both independent variables and dependent variables that had a major impact on porosity inside the 15L block. The study leads to final root cause analysis for the porosity defect, for over a $ 1M a month in cost saving.
• G-Tech Services, Inc, Dearborn, MI, Sr. Proactive Reliability, Strategy & Implementation Engineer, 9/2009 to 1/2010, I conducted APQP and PPAP with all the Suppliers for the Foundries - Parts-Engine, Brackets, Casting parts, Injection Molding, Body Parts, and Machining & Welding Bracket parts.
• G & D MANAGEMENT REAL ESTATE, West Bloomfield, MI, Quality Project Manager/Engineering/ Quality Manager, 2/2003 to 2006, Negotiated the acquisition of $2.5 Million for Real Estate property, supervised real estate team and, writing capital projects, Detect costly errors, reduced heating by 70 %, electrical by 20%. Improved renovation turnaround time to 15% in one year and improved plumbing contractor cost by 15%, Managed and supervised a Cross –Functional Engineering Team of (15)-engineers
• GENERAL MOTOR (GMPT), Pontiac, MI, Sr. Project/Supplier Quality/ Operation / Engineering Supervisor, Mar 2007 –July 2008, Leads discussions that impact or change global project PPAP, APQP, GP9, GP12 and PSO, Identify risks and execute mitigation plans. Identify issues and execute resolution., Collaborated with cross-functional teams to address Quality defects in the manufacturing process for QR & Warranty return for a , contributing to a 10% reduction in overall defect rates.
• DAIMLERCHRYSLER, Detroit, Michigan, Sr. Lead Resident Engineer Supervisor/ Team Leader, Process Engineer Team Leader, ISO/QS9000 Engineer Team Leader, Product Engineer Team Leader, and JD Power Engineer Leader, 06/1994 to 04/2003, Supervised, (18) engineers, BSR, Six Sigma Process Improvements, developed, Trained, coached, mentor, and Quality, Process, Product, ISO/QS, and SQA Eng. Developed new short test BSR track six sigma projects save 1.2 million dollars in cost saving for BSR testing., Completed all in line process testing for the Hvac sytems in the plant. Work with the suppliers on their PFMEA and DFMEA for their system, to reduce (RPN) in their FMEA., PPAP’s all the Aluminum evaporators and Condenser with the suppliers, to ensure that they meet all of our requirements for, MSA, DFMEA, PFMEA, Gauge R&R, Control Plans, DVP&R testing, Cp&CpK studies , and drawing requirements.