Karen Smith Sullivan
Bardstown,KY
Summary
Results-driven Quality Manager with a proven track record of 25 years in achieving exceptional quality control outcomes. Skilled in developing precise and measurable goals, improvements, and standards to drive continuous enhancement of quality while minimizing errors. Proficient in conducting thorough audits to ensure product accuracy and timely delivery, resulting in high levels of customer satisfaction. Adept at initiating comprehensive SOP training programs and enforcing strict procedural adherence to maintain optimal quality standards.
Overview
34
34
years of professional experience
1
1
Certification
Work History
Quality Manager
Katayama American Company
07.2022 - Current
- Responsible for overall Plant Quality from Receiving to Final shipping
- Leading representative for ISO/IATF Certification maintenance to final result and countermeasure activity·
- Schedule and facilitate annual Executive Management reviews as part of the IATF Standard Requirements
- Weekly lead management KPI meetings with closure of top Items
- Manage implementation of and compliance with all quality management systems including documentation, internal and external audits. Implementation of Intellaquest system for document control and PFMEA/ PQCT
- Responsible for all Customer Interactions with a track record of excellent relationship building and collaboration
- Responsible for Setting Team and Department goals
- Mentored and encouraged employees to strive for excellence while fostering professional growth.
- Equipped and organized facility to comply with company strategy for online and offline quality controls.
- Responsible for 22 Direct Reports including Quality engineers and Quality Techs with Goal Setting and feedback
- Developed new standard work with sequencing and key criteria for training purposed
- Dojo /Training center development with hands-on training and SOP Training
- Plant A3 Problem solving training for Scrap Reduction.
- single point of accountability for providing satisfactory responses to all audit NCRs and findings in order to maintain certifications.
- ·Periodically review all management system documentation to determine if it is up to date and accurate.
- Make changes to documentation and revision levels as needed.
- · Responsible for ensuring appropriate storage and control of all management system documents and records.
- · Perform All duties necessary to ensure compliance with management systems and preparedness for audits.
- · Research, respond and drive closure to NCRs and service incidents, as needed to ensure timely responses to customers by utilizing Quick Response Quality Control
- · Utilize and analyze Key Performance Indicators to drive continuous improvement.
- · Develop KPI's for Scrap and Customer concerns and create standard reports.
- Develop and conduct training.
- Champion and leader for management of change and continuous improvement.
- Key Process Outputs of Position.
- Review of management system documentation and records Documentation of annual Executive Management System.
- Reviews Internal and external audit schedules Internal audit reports.
- Responses to all ISO/ IATF audit NCRs and findings and communication to the team
- Proactive Approach to Documentation and records of facts, root cause(s) and conclusions of fault for some NCRs, claims and potential claims.
Quality Manager
Johnan America
06.2018 - 01.2022
- Responsible for the development and successful implementation of IATF Certification with Johnan America
- Development FMDS (Floor Management Development System) which is a visual management of change
- Continuous Improvement Leader with the introduction of SOP's and training
- Direct Customer contact for External Complaints and resolution of NCR's and quick response
- Responsible for Supplier Charge back tracking
- Management of five Quality Engineer’s, Lab Supervisor and nine Quality Auditors with goal setting and follow through
- Implementation of KATA/ PDCA Improvement Activity / Training for continuous improvement activities
Quality Manager
PTI
01.2017 - 01.2018
- Implementation of IATF16949 Plant wide for the initiation of the certification for the plant
- Responsible for Chemical Controls for Titration (Automotive paint application) Techs responsible for chemical related processes
- Maintain and develop PFMEA and Control Plans for all processes including HR
- Responsible for maintaining Document Control for IATF 16949
- Implementation of Enterprise Risk Management ISO 33000
- Responsible for increasing FTQ% by 50%
- Expert at 8D Problem solving format.
Quality Manager
Amaray Plastics
01.2015 - 01.2017
- Customer Quality Metrics- Improvement 80% Jan- June
- Implemented self training education center for new and veteran team members
- Responsible for ISO Certification maintenance
- Implementation Auto DCP program-PFMEA/Control plan
- Responsible for Kaizen Activity for continuous improvement-Savings 100k+
- Implemented 8D Problem solving teams on the plant floor
- Implemented sequenced work instructions within the plant
- Implemented defect detection system
- Process failure modes additions to prevent flow out (vision systems)
- Visual management system of daily issues for tracking and analysis
- Supplier quality visits to investigate / implement changes for improvement
- Established close knit customer relationships for handling Quality concerns.
Quality Manager
Johnson Controls
01.2014 - 01.2015
- Quality Improvement Metrics Plant wide
- Q1 Flag recovery Chairperson
- Layered Process Audit System Chairperson
- Responsible for five Quality Engineer’s, three Quality Control Supervisors and twelve auditors.
Quality Engineer/Quality Lab Supervisor
Johnson Controls
01.2011 - 01.2014
- Responsible for Supplier Countermeasure Activity
- Responsible for Customer Quality and Problem Solving
- Brought Avalon Quality from 4.0 Appearance score to 4.8 to attain Lexus Business
- Set up of Inspection and Assembly Fundamental Skill Training area
- Developed Process Change Management System
- Floor Management Development system Implementation
- Standard Work Revision /Training System Plant wide
- Problem Solving Team Development Plant wide.
Quality Control Supervisor
Toyota Motor Manufacturing
01.2002 - 01.2009
- Supervised 28 team members in Quality Control Department
- Trained/Supervised new team leaders to hold supervisory roles
- Responsible for writing and presenting quality control reports
- Worked closely with Human Resources to resolve manpower issues
- Facilitated problem solving within and between other departments
- Evaluated employees’ job performances and gave review
- Understanding of Receiving Inspection involving Materials Quality, Body Weld Quality Measurement, Paint /E-Coat Quality with Inspection, Engine Quality and Stamping Quality pertaining to weld strength and specifications.
Quality / Power train Production Team Member
Toyota Motor Manufacturing
01.1991 - 01.2002
- Team Member in machining in Power Train Department
- Created standard work processes for machining department
- Created training manual for tool adjustments
- Developed and presented training for other team members
- Safety leader and Quality Circle leader in Power Train
- Worked with outside vendors to design and improve processes.
Education
Sullivan University
University of Mississippi
BA -
Eastern Kentucky University
01.1990
Skills
- Excel
- Microsoft Word
- Power point
- Lotus Notes
- ISO/IATF Auditor
- Familiarity with quality standards
- Team Training
- Problem-solving abilities
- Market research experience
References
Upon Request
Extracurricular Activities
Golf Running Frisbee golf bicycling photography
Community Service
Volunteer, Women’s First Cancer Center, Tupelo, MS, 2010
Certification
- CQM - Certified Quality Manager
- ISO/ IATF Training - 2018-2024
Timeline
Quality Manager
Katayama American Company
07.2022 - Current
Quality Manager
Johnan America
06.2018 - 01.2022
Quality Manager
PTI
01.2017 - 01.2018
Quality Manager
Amaray Plastics
01.2015 - 01.2017
Quality Manager
Johnson Controls
01.2014 - 01.2015
Quality Engineer/Quality Lab Supervisor
Johnson Controls
01.2011 - 01.2014
Quality Control Supervisor
Toyota Motor Manufacturing
01.2002 - 01.2009
Quality / Power train Production Team Member
Toyota Motor Manufacturing
01.1991 - 01.2002
Sullivan University
University of Mississippi
BA -
Eastern Kentucky University
- CQM - Certified Quality Manager
- ISO/ IATF Training - 2018-2024
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