JAMES JOHNSON

• Communicate directly with Tier 1 automotive customers, specifically General Motors, Stellantis, Navistar and Subaru, regarding Quality related issues.
• Develop and create PFMEA, Control Plan, Process Flow Diagram, MSA and SPC documentation.
• Complete PPAP packages for new or changed products and submit to customers in their required formats.
• Champion Corrective Action teams to determine core reason for failures and errors through use of 8D, Ishikawa Diagrams, 3 Legged 5 Whys, Fault Tree Analysis and other customer forms as required.
• Develop process improvements to systems, drive implementation and maintain current quality systems to achieve internal KPI's.
• Compile statistical analysis of process data and report to internal management and customers.
• Develop training materials and perform employee training.
• Reported on non-compliance issues and other negative factors discovered during production.
• Recommended revisions to internal controls and operational and management policies and procedures.
• Escalated concerns about project and process quality, referring discovered issues to management for correction.
• Performed quality inspections and drafted reports to detail non-conforming material issues.
• Partnered with senior management to analyze issues and find appropriate solutions.
• Facilitated process improvements to successfully decrease errors.
• Executed IATF Internal Audits.
• Analyzed and interpreted customer requirements for development of quality documentation.
• Trained and mentored junior engineers, providing guidance and direction.
• Conducted technical evaluations of test results.

Layoff due to COVID 19 economic downturn.

• Responsible for the overall quality system at the Helenwood Facility.
• Manage and coordinate activities of QA and QC Departments consisting of 2 QC Supervisors, 9 QC Lab Technicians, 16 QC Inspectors on 4 shifts, 2 QA Engineers, 1 QA PPAP Specialist, 1 Document Control Specialist, and 1 IATF16949 Coordinator.
• Successfully coordinated two IATF16949 audits resulting in no major findings.
• Create and present KPI presentations to Management at monthly staff meetings.
• Coordinated and oversaw periodic audits to evaluate product quality and safety and address non-conformances.
• Managed and archived quality documentation and participated in internal and external quality audits.
• Updated quality control standards, methods, and procedures to meet compliance requirements.
• Increased customer satisfaction through adherence to quality standards and customer requirements.
• Improved quality processes for increased efficiency and effectiveness.
• Mentored and encouraged employees to strive for excellence while fostering professional growth.
• Liaised with HR manager to organize and perform quality standard training for new and existing staff.
• Maintained positive customer relations by addressing problems head-on and implementing successful corrective actions.
• Evaluated employee performance and conveyed constructive feedback to improve skills.
• Used industry expertise, customer service skills and analytical nature to resolve customer concerns and promote loyalty.
• Defined clear targets and objectives and communicated to other team members.
• Recruited, interviewed and hired employees and implemented mentoring program to promote positive feedback and engagement.
• Successfully managed budgets and allocated resources to maximize productivity and profitability.
• Controlled resources and assets for department activities to meet budgeted requirements.

• Responsible for quality system implementation, maintenance and performance at Firestone's Williamsburg facility.
• Manage QA Department consisting of 13 Inspectors on 4 shifts, 4 QA Engineers, 2 QA Specialists and 1 Document Control Clerk
• Led development and implementation of action plans to successfully achieve ISO 9000; QS9000; and TS16949 on initial registration audits.
• Coordinated 35 third party quality system certification audits and 50 plus customer audits.
• Created and implemented databases to improve QA Department data tracking and reporting.
• Improved inspection processes to avoid QA department manning increases.
• Led process improvement projects to help operations meet and exceed quality standards and reduce costs.
• Facilitated continual improvement as Six Sigma Black Belt Leader.
• Developed and implemented Document Control system, tracking in excess of 3,000 documents.
• Edited, proofed and critiqued internal documents to improve clarity.
• Compiled, lead, and reported monthly Management Review meetings covering 30 plus KPIs.
• Drafted performance and quality assurance reports and presented findings at daily Gemba walks.
• Created and revised procedures, checklists and job aids to reduce errors.
• Defined and implemented quality initiatives to reduce risk.
• Administered 43 internal quality audits and assessed results to develop corrective action measures.
• Analyzed quality and performance data to support operational decision-making.
• Performed standard first article inspections and random sampling inspections to verify adherence to customer standards.
• Created, implemented and maintained customer complaint log.

• Developed and implemented quality system manual and procedures for start-up of Williamsburg facility.
• Developed and coordinated actions to successfully achieve Ford Q-101 status for facility.
• Developed Control Plans, PFMEA, Process Flow Diagrams and performed PPAP's in preparation for customer's product launches.
• Proposed development and testing improvements to positively impact usability, function and performance.
• Met tight deadlines to satisfy client demands and project timelines.
• Produced and maintained technical documentation for project reference.
• Drove corrective actions to accomplish project closure and recurrence control.