Michael Boerner
Hutto,TX
Summary
Over 28 years in Automotive Manufacturing and over 22 years in Quality. Possess the ability to support the needs of production as well as new program launch activities. Currently seeking a Quality Director/Manager position.
Overview
28
28
years of professional experience
Work History
Central Quality Manager
Tesla
12.2022 - 04.2024
- Managed QMS, Metrology Lab, Materials Lab, Calibration Team, Global Audit Team, and Weld Tear Down Lab initiation, development, and operations totaling 91 personnel.
- Managed team of 91 personnel, planned for 135, in support of 10M square foot facility with 2 models of vehicle.
- Developed, enhanced, and tracked KPIs and plan for all departmental improvement for all departments showing improvements that were ahead of schedule.
- Introduced and developed QMS kick-off strategy including performing gap analysis and structuring quarterly approach to show plan of activities to completion within 2 years.
- Originated Calibration department and systems allowing plant activities to recover over 7400 tools either not tracked or late for calibration.
- Harmonized Global Audit (final vehicle audit) system between 4 OEM facilities to allow systematic approach and scoring structure of audits.
- Grew Materials department from working within 800 square foot temporary space with 3 Engineers and 4 Technicians with basic equipment to working in new design 7000 square foot location with 16 Technicians and 4 Engineers.
- Advanced Metrology department and plant to incorporate new testing technologies allowing plant to adjust production needs to improve FPY (RFT), internal scrap, and warranty issues.
- Revamped Weld Tear Down (WTD) department to allow proper support of Model Y (current production), Cybertruck (newly launched), and upcoming launch of 3rd vehicle.
Quality Manager
Toyota-Boshoku
04.2021 - 12.2022
- Oversaw and involved in IATF16949 certification process from project initiation to certification receipt.
- Trained department personnel on Gage R&R (MSA) requirements and ensured study completion.
- Instituted SPC systems in assembly and weld operations, including training, procedure writing, reaction plans across multiple departments.
- Instructed and performed Critical process audits supporting PRCC process and plant management readiness (PMR) audits, with accompanying kaizen plans, to improve plant quality operations.
- Assisted with corrective action process by improving tools allowing for proper understanding of defining problem and root cause analysis resulting in improvement of Customer score card rank to level “A” at TMMI.
- Revamp calibration system, initially showing over 50% of gages/tools past due, to incorporate use of on-sight 3rd party calibration activities to address current needs as well as developed full calibration system that allowed proper tracking, communication, and visualization of status
Program Manager
Toyota-Boshoku
04.2017 - 04.2021
- Direct 2 new projects toward desired business results through coordination of SPD process, including project profitability, development, and approval of project plans.
- Monitor project activities for compliance with company procedures, conformation to project scope and follow scope change, notification, and approval.
- Conflict resolution, priority setting, risk assessment and planning within SPD process guidelines.
- Act as customer liaison, preparing and reviewing program statuses with customer.
- Direct team to achieve overall customer satisfaction, negotiating requirements of Customer.
- Conduct reviews for: tooling, assemblies, fixtures, designs, supplier readiness, lessons learned, cost targets, profit margin, investment, piece price, manufacturing readiness and production piece manufacturing.
Quality Manager
Faurecia Automotive
05.2015 - 04.2017
- Responsible for overall Quality Key Performance Indicators for 7 manufacturing facilities through management of QA Managers for these facilities.
- Managed team of 74 personnel including Program QA Leads, SQ Engineers, and lab testing personnel at Corporate offices.
- Controlled departmental budget obtaining 12.7% reduction compared to budget in 2015.
- Train departmental and plant personnel on Corporate and Customer standards.
- Perform hiring, discipline, and dismissals for department with assistance from HR.
- Lead QA launch activities teams for Cadillac CT6, Ford P558, and multiple platforms for light, medium, and heavy-duty Nissan, Ford, and Cummins programs in Greenfield and Brownfield facilities.
- Ensured development, implementation, training, and enforcement of systems and procedures.
- Assist Operations with updates and understanding of Customer requirements.
- Chair daily, weekly, and monthly department meetings to ensure progress of improvement actions.
- Act as Customer voice to ensure Customer expectations are delivered.
- Direct Supplier Quality initiatives to ensure issues are under control while maintaining good Supplier relations.
- Complete monthly, quarterly, semiannual, and annual personnel and plant quality performance evaluations.
Education
IATF-16949 and ISO-9001 Lead Auditor Certified - Lead QMS Auditor IATF 16949:2016/ISO 9001:2015
Omnex Engineering & Management, Inc.
Ann Arbor, MI06.2021
Powerway Administrator training, Intier Automotive -
Inter Aujtomotive
Milan, TN01.2003
DOE training, Guardian Automotive -
Guardian Automotive
Auburn Hills, MI01.2002
Some College (No Degree) - Mechanical Engineering Technology
Purdue University Calumet
Hammond, INISO-9000 Lead Auditor Certified, Thomas & Betts - Lead QMS Auditor ISO 9001
Thomas & Betts
Romeoville, IL01.2000
PPAP/APQP/FMEA/SPC/MSA/QSA training, Lear Corp. -
Lear Corporation
Hammond, IN01.1996
Skills
- Defect Tracking Management
- Corrective and Preventive Actions
- Control Plan Development
- CAPA Investigations
- Quality Management Systems
- Failure Modes and Effects Analysis
- Lean manufacturing principles
- Measurement System Analysis
- ISO 9001 compliance
- Process Validation Techniques
- Process Capability Studies
- Performance Testing Strategies
- Customer Service
- Multitasking and Organization
- Complex Problem-Solving
- Continuous Improvement
Work Availability
monday
tuesday
wednesday
thursday
friday
saturday
sunday
morning
afternoon
evening
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Timeline
Central Quality Manager
Tesla
12.2022 - 04.2024
Quality Manager
Toyota-Boshoku
04.2021 - 12.2022
Program Manager
Toyota-Boshoku
04.2017 - 04.2021
Quality Manager
Faurecia Automotive
05.2015 - 04.2017
IATF-16949 and ISO-9001 Lead Auditor Certified - Lead QMS Auditor IATF 16949:2016/ISO 9001:2015
Omnex Engineering & Management, Inc.
Powerway Administrator training, Intier Automotive -
Inter Aujtomotive
DOE training, Guardian Automotive -
Guardian Automotive
Some College (No Degree) - Mechanical Engineering Technology
Purdue University Calumet
ISO-9000 Lead Auditor Certified, Thomas & Betts - Lead QMS Auditor ISO 9001
Thomas & Betts
PPAP/APQP/FMEA/SPC/MSA/QSA training, Lear Corp. -
Lear Corporation