R. Gregory Bayly
Blenheim
Summary
Quality engineering professional with extensive experience at Woodbridge Foam, specializing in quality assurance and supplier development. Demonstrated success in process improvement and data analysis, resulting in significant enhancements in product quality. Skilled in leading cross-functional teams and building strong supplier relationships to ensure compliance and operational excellence.
Overview
32
32
years of professional experience
Work History
Sr. Supplier Development Quality Engineer
Woodbridge Foam
Troy
04.2013 - Current
- Monitored launch readiness and PPAP approvals for Molded and EPP B/U WBF programs, ensuring supplier compliance and timely project execution.
- Partnered with production teams to identify and resolve quality issues, leading to improved process reliability.
- Conducted training on quality assurance best practices and inspection techniques.
- Analyzed data from quality reports to uncover trends and areas needing improvement.
- Coordinated internal audits to ensure compliance with industry regulations and standards.
- Led root cause analysis meetings to systematically address and mitigate recurring quality issues.
- Reviewed engineering drawings, process specifications, and technical documents for accuracy.
- Established and monitored KPIs to evaluate quality objectives.
Quality Manager/ Sr. Quality Engineer
Woodbridge Foam
Blenheim
04.2008 - 04.2013
- Developed and maintained quality systems for customers and suppliers on FIP line
- Assisted in implementing quality initiatives across the plant
- Developed quality assurance procedures for foam manufacturing processes.
- Conducted regular audits to ensure compliance with industry standards.
- Trained staff on quality control techniques and best practices.
Quality Engineering/Supplier Specialist
SETEX Canada – JCI & Tachi-S Joint Venture
Shelburne
04.2004 - 04.2008
- Track supplier issues, part changes and corrective actions to timely closure – utilizing SMRR & CA/CN database and I.P.P. system.
- Evaluate proposed changes in design, process and materials to current specifications.
- Perform and validate process capability on all new tooling, processes and equipment.
- Investigated problems, coordinated corrective actions, and followed up with customers and suppliers on countermeasures.
- Assisted suppliers in developing quality systems to enhance product quality and reduce costs.
- Conduct audits to ensure compliance with quality standards
- Customer contact for any problems, design issues, countermeasures and responsible for written and verbal communications to all pertinent personnel.
- Review technical publication to determine possible application of new methods.
- Managed supplier AQP for new programs, ensuring compliance with quality standards.
Quality Engineering/Supplier Supervisor
Integram Seating System, Magna Corporation
Tecumseh
04.1999 - 01.2004
- Led quality processes as the PSO/PPAP Champion for the DaimlerChrysler Minivan Seating Program.
- Coordinated and assisted Quality Engineering and Supplier Quality activities for automotive seating programs (DaimlerChrysler Minivan RS & CS), supervising quality engineering and supplier quality disciplines.
- Developed, implemented, maintained, and improved processes for design, engineering, manufacturing, and quality, focusing on waste elimination and problem prevention.
- Supported and coordinated quality responsibilities for new and redesigned programs and components related to plant operations.
- Support and be lead contact for Customer issues and New program launches within the Quality discipline
- Maintain and co-ordinate activities within the lab testing responsibilities
Production General Supervisor
LEAR Corporation
St. Thomas
09.1994 - 02.1998
- Managed plant operations by scheduling and controlling hourly production requirements to meet production goals.
- Ensured on-time delivery of quality products to protect customer satisfaction.
- Improve First Run Capability (i.e. - Reduce Scrap & Rework, Improve Product Quality through Engineering Tryouts of Design/Process changes)
- Assist and direct the Production Supervisors with administration of the Collective Agreement and company policies.
- Coach/Train the Line Supervisors to utilize the tools and experience
- Coach/Train my Supervisors in different theories and concepts of Manufacturing Techniques.
- Facilitated employee relations by utilizing the Collective Agreement and conducting mutual talks with over 120 employees.
- Assisted and supported the Operations Manager.
Education
Project Management -
Magna Training Center
NOVI, Michigan, USE10-2002
QS9000 General Training -
Magna Training Center
Tecumseh, Ontario, Canada07-2002
DaimlerChrysler SPIN System (DCX Engineering Change Control & Corrective Action System) -
Magna Training Center
Tecumseh, Ontario, Canada07-2000
Advanced Product Quality Planning and Production Part Approval Process -
STAT-A-MATRIX INSTITUTE
Princeton, New Jersey, USA09-1997
Basic WERS Training (FORD Engineering Change Control System) -
FORD Training Institute
Dearborn, Michigan, USA06-1996
Geometric Dimensioning & Tolerancing ASME Y14.5 1994 -
Premier Solutions Group
St. Thomas, Ontario, Canada06-1996
Advanced Dimensional Metrology; Surface Roughness/Roundness/Hardness -
Mitutoyo
Toronto, Ontario, Canada11-1994
Gage Calibration Systems for Dimensional Metrology -
Mitutoyo
Toronto, Ontario, Canada11-1994
Statistical Process Control -
Scholfield Consulting Services
Toronto, Ontario, Canada07-1994
Manufacturing Engineering Technology -
Sir Sandford Fleming College
Peterborough, Ontario, Canada12-1993
Skills
- Supplier development
- Quality assurance
- PPAP management
- Quality assurance and internal auditing
- Process improvement strategies
- Data analysis and root cause analysis
- Data analysis
- Risk management
References
Available on request
Timeline
Sr. Supplier Development Quality Engineer
Woodbridge Foam
04.2013 - Current
Quality Manager/ Sr. Quality Engineer
Woodbridge Foam
04.2008 - 04.2013
Quality Engineering/Supplier Specialist
SETEX Canada – JCI & Tachi-S Joint Venture
04.2004 - 04.2008
Quality Engineering/Supplier Supervisor
Integram Seating System, Magna Corporation
04.1999 - 01.2004
Production General Supervisor
LEAR Corporation
09.1994 - 02.1998
Project Management -
Magna Training Center
QS9000 General Training -
Magna Training Center
DaimlerChrysler SPIN System (DCX Engineering Change Control & Corrective Action System) -
Magna Training Center
Advanced Product Quality Planning and Production Part Approval Process -
STAT-A-MATRIX INSTITUTE
Basic WERS Training (FORD Engineering Change Control System) -
FORD Training Institute
Geometric Dimensioning & Tolerancing ASME Y14.5 1994 -
Premier Solutions Group
Advanced Dimensional Metrology; Surface Roughness/Roundness/Hardness -
Mitutoyo
Gage Calibration Systems for Dimensional Metrology -
Mitutoyo
Statistical Process Control -
Scholfield Consulting Services
Manufacturing Engineering Technology -
Sir Sandford Fleming College