Todd Kerby
Huntsville,AL
Summary
Effective quality professional bringing proven success in driving continuous improvement initiatives in Quality Engineer roles. Focused and diligent with commitment to fostering corporate mission. Consistently acknowledged for implementing actionable initiative to reduce error rates and optimize company processes.
Overview
13
13
years of professional experience
1
1
Certification
Work History
Quality Engineer III
ZIN Technologies
09.2023 - Current
- Evaluation of commercial launch provider's Quality Management System (QMS) and all associated sub-systems
- Evaluate and provide feedback on launch provider's nonconformance and corrective/preventative actions systems
- Participate in, and provide quality engineering analysis for NASA certification processes for new or upgraded hardware
- Present quality engineering information at various NASA Safety and Quality meetings
- Provide coordination with other quality engineering and assurance support as required (e.g., DCMA,USAF SMC)
- Evaluate and provide feedback on launch provider's Supply Chain Management and Procurement Quality Processes
- Participate in various audits of commercial launch provider's QMS (e.g., supplier, internal, AS9100 3rdparty) as required
- Perform analysis of contractor quality and supplier quality performance data to include trending and risk analysis input
- Assist the NASA S&MA office with identifying safety concerns while monitoring commercial launch provider manufacturing
- Created and maintained supplier nonconformance and performance tracking sheets
- Analyzed metric data from supplier tracking sheets to generate audit NASA supplier audit schedule
Lead Technologist - Quality Assurance Advisor
Booz-Allen & Hamilton
05.2023 - 09.2023
- Enhanced product quality by implementing rigorous inspection procedures and conducting thorough root cause analysis.
- Reduced production defects by designing and executing comprehensive quality control processes.
- Improved customer satisfaction levels with timely resolution of non-conformance issues and effective corrective actions.
- Streamlined internal communication, fostering cross-functional collaboration between engineering, manufacturing, and quality teams.
- Conducted detailed audits to ensure adherence to ISO 9001 standards, maintaining a high level of compliance throughout the organization.
- Optimized supplier performance through regular assessment and feedback, leading to increased product reliability and cost savings.
- Implemented process improvements based on Lean Six Sigma methodologies, resulting in reduced waste and increased efficiency.
- Facilitated training sessions for team members on quality management principles and best practices, enhancing overall competency levels within the department.
- Collaborated with external auditors during annual reviews, ensuring a seamless audit process with minimal findings or discrepancies noted.
- Developed inspection plans based on design specifications, ensuring all critical dimensions and performance criteria were verified throughout the manufacturing process.
- Supported organizational growth initiatives by participating in new business proposals or customer presentations showcasing the company''s commitment to delivering high-quality products.
- Contributed to root cause analysis to determine core reason for failures and errors.
- Performed quality inspections and drafted reports to detail non-conforming material issues.
- Researched and evaluated new techniques and technologies to improve product quality.
- Managed and maintained calibration system
- Experienced in collaborating with multifunctional teams of engineers, logistics specialists, quality specialists, fielding managers, system acquisition managers, procurement analysts, budget managers,defense contractors, test and evaluation directors, or contracting officers to certify and quality advance manufacturing technology
Lead Quality Engineer
Dynetics
10.2020 - 05.2023
- Improved product quality by developing and implementing comprehensive testing strategies.
- Led a team of engineers to identify and resolve critical defects, ensuring customer satisfaction.
- Reduced production delays by streamlining the quality control process for efficient workflow.
- Enhanced overall product performance through rigorous analysis of manufacturing processes.
- Collaborated with cross-functional teams to address recurring issues, increasing efficiency and reducing costs.
- Performed regular audits on suppliers to ensure adherence to strict quality standards, maintaining strong partnerships and vendor relations.
- Conducted root cause analyses for major defects, leading to effective corrective actions preventing future occurrences.
- Implemented continuous improvement initiatives to optimize product design, resulting in higher durability and reliability.
- Coordinated with regulatory agencies to ensure compliance with industry-specific rules and regulations pertaining to product safety and performance requirements.
- Championed Lean Manufacturing principles within the engineering team, cultivating a mindset of continuous improvement throughout operations.
- Established robust documentation protocols for test results and non-conformance reports, supporting traceability and transparency in decision-making processes.
- Evaluated new technologies for potential integration into existing systems, staying at the forefront of industry advancements in manufacturing techniques or materials science breakthroughs as they emerged.
- Facilitated cross-training among team members for enhanced knowledge sharing and skill diversification, fostering a versatile workforce capable of tackling various challenges in the ever-evolving field of engineering.
- Led problem-solving activities (8D problem solving method and 5 Why methodology) to quickly identify and permanently resolve quality and productivity issues.
- Facilitated process improvements to successfully decrease errors.
- Partnered with senior management to analyze issues and find appropriate solutions.
- Researched and evaluated new techniques and technologies to improve product quality.
- Escalated concerns about project and process quality, referring discovered issues to engineering manager for correction.
- Recommended revisions to internal controls and operational and management policies and procedures.
- Developed and implemented comprehensive quality assurance program to guarantee organization products met safety and quality standards.
- Utilized Agile and Waterfall methodologies of Project Management to ensure proper compliance and completion of all Quality functions of assigned programs.
- Review and interpret contract quality clauses and statements of work to develop appropriate quality procedures, plans, and work instructions.
Quality Engineer II
ZIN Technologies
07.2020 - 09.2020
- Evaluation of commercial launch provider's Quality Management System (QMS) and all associated sub-systems
- Evaluate and provide feedback on launch provider's nonconformance and corrective/preventative actions systems
- Participate in, and provide quality engineering analysis for NASA certification processes for new or upgraded hardware
- Present quality engineering information at various NASA Safety and Quality meetings
- Provide coordination with other quality engineering and assurance support as required (e.g., DCMA,USAF SMC)
- Evaluate and provide feedback on launch provider's Supply Chain Management and Procurement Quality Processes
- Participate in various audits of commercial launch provider's QMS (e.g., supplier, internal, AS9100 3rdparty) as required
- Perform analysis of contractor quality and supplier quality performance data to include trending and risk analysis input
- Assist the NASA S&MA office with identifying safety concerns while monitoring commercial launch provider manufacturing
Quality Control and Inspection Supervisor
RUAG Aerospace
05.2018 - 06.2020
- Experienced in the construction and inspection of complex, large-scale, out-of-autoclave, carbon fiber composite structures
- Improved inspection process efficiency by streamlining workflows and implementing new procedures.
- Enhanced team performance through regular training sessions and performance evaluations.
- Reduced inspection errors by implementing a robust quality control system.
- Increased productivity by effectively allocating resources and optimizing schedules for inspections.
- Ensured compliance with industry standards and regulations through thorough inspections and rigorous documentation practices.
- Collaborated with cross-functional teams to address inspection-related issues, resulting in improved workplace safety.
- Mentored junior inspectors, providing guidance on best practices and fostering professional growth.
- Developed inspection checklists to standardize processes, leading to consistent results across the department.
- Managed budgetary constraints while ensuring necessary resources were available for effective inspections.
- Utilized advanced inspection tools and techniques to accurately assess complex systems or structures.
- Coordinated with project managers for efficient scheduling of inspections within tight deadlines without compromising quality or accuracy.
- Evaluated emerging trends in the industry to recommend improvements in inspection methodologies or technologies.
- Resolved conflicts amongst team members efficiently while maintaining clear lines of authority within the department.
- Promoted a culture of continuous improvement within the department by encouraging feedback from team members on existing processes.
- Supervised ongoing daily production phases.
- Collaborated with other leaders and executives to direct workflow and support operations.
- Planned, organized and monitored resources to deliver efficient use of labor, equipment and materials.
- Managed staff hiring, training and supervision.
- Kept accurate and detailed records of personnel progress and productivity.
- Monitored daily and weekly key performance indicators to maintain on-track status.
- Completion of KUKA Robotics Programming 1, used to facilitate NDT activities
- GIDEP administrator for Decatur, AL facility
- Manager of Calibrated Equipment for Decatur, AL facility
- Assist Quality Engineering team with the completion of acceptance data packages for customers,including thorough analysis of As Built/As Design, material and process certification, and configuration management.
- Work with outside vendors to complete various projects, i.e., large-scale equipment calibrations, construction projects, and new equipment purchasing and implementation
Quality Control Technician
Toyota Motor Manufacturing Alabama
12.2010 - 05.2018
- Enhanced product quality by conducting comprehensive inspections and identifying defects in a timely manner.
- Implemented process improvements for increased efficiency and reduced waste in quality control procedures.
- Collaborated with production teams to address and resolve quality concerns, improving overall product reliability.
- Conducted thorough root cause analysis for recurring issues, leading to targeted corrective actions and continuous improvement.
- Assisted management in maintaining ISO certification through diligent documentation and adherence to established protocols.
- Developed and executed test plans to ensure products met customer specifications, increasing client satisfaction rates.
- Trained new team members on proper quality control techniques, fostering a culture of excellence within the department.
- Analyzed data trends to identify areas of concern and recommend proactive solutions, resulting in fewer product returns.
- Maintained accurate records of all quality control activities, ensuring easy retrieval for audits or management inquiries.
- Conducted regular internal audits to assess compliance with company policies and regulatory requirements, driving continuous improvement efforts.
- Championed a culture of safety by strictly adhering to established protocols and promoting awareness among team members.
- Performed thorough inspections of incoming materials and outgoing products.
- Inspected raw materials and finished products to verify quality and disposed items that did not meet safety requirements.
- Maintained quality documentation and records for conformance with relevant standards.
- Travel to other Toyota manufacturing facilities and lead rework/repair activities.
- Perform engine function and diagnostic testing based on engineering test plans.
- Became certified Toyota Ergonomics Assessor to provide support in creation of new processes.
Education
High School Diploma -
Lawrence County High School
Moulton, AL05.2001
Skills
- Technical Writing
- Team Collaboration
- Critical Thinking
- Process Change Documentation
- Non-Conforming Materials Report
- Quantitative Analysis
- Root Cause Analysis
- Project Scheduling
Certification
Google Project Management
Earned in June 2022
Verify this certificate at: https://coursera.org/verify/profession al-cert/NWNFEJYWFB5F
Lean Six Sigma Green Belt
Earned in March 2023
Certification granted from Dynetics University
Timeline
Quality Engineer III
ZIN Technologies
09.2023 - Current
Lead Technologist - Quality Assurance Advisor
Booz-Allen & Hamilton
05.2023 - 09.2023
Lead Quality Engineer
Dynetics
10.2020 - 05.2023
Quality Engineer II
ZIN Technologies
07.2020 - 09.2020
Quality Control and Inspection Supervisor
RUAG Aerospace
05.2018 - 06.2020
Quality Control Technician
Toyota Motor Manufacturing Alabama
12.2010 - 05.2018
High School Diploma -
Lawrence County High School
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