Zachary Couchman
Layton,Utah
Summary
Quality control professional experienced in developing organization's quality strategy, procedures and processes. Monitor quality performance from supply chain and throughout product development life cycle. Develop and sustain Quality Management System in accordance with ISO 9001/AS9100 and other applicable standards and business requirements. Manage quality audit program to identify and resolve non-conformities and embed culture of continuous improvement.
Overview
16
16
years of professional experience
1
1
Certification
Work History
Director of Quality
Optisys, LLC
08.2020 - 03.2024
- Championed growth of company-wide Quality culture resulting in: Reduced monthly scrap rates by 15%, Reduced monthly NC rate by more than 10%
- Achieved highest available supplier rating for three top customers
- Reduced Corrective Action closure time by 58% over 6-month period and Reduced # of open corrective actions by 92% over a 6-month period.
- Drove overhaul of Quality Management system to meet aerospace and defense industry standards; including re-writing of quality manual.
- Drove overhaul of Supplier Quality system, measuring supplier conformity, improving supplier on-boarding, and fostering improved communication and collaboration between Optisys and suppliers.
- Lead team of quality professionals, growing team from one to five people with four direct reports.
- Company Quality Management Representative–face of the company for third party and customer audits–leading efforts to maintain ISO9001/AS9100 and ISO-13485 certifications, Performed source inspections for various programs
- Oversaw implementation of Hexagon Optiv 6.6.4 CMM, Program and operate Hexagon Optiv 6.6.4 CMM with PC-DMIS.
- Program and operation Keyence XM CMM.
- Perform inspections using numerous metrology tools including calipers, micrometers, pin gages, etc.
- Quality subject matter expert for ERP system.
- Manage Quality Engineering duties for production programs.
Quality Engineering Technician
PCC Structurals
06.2019 - 05.2020
- Served as customer liaison for the steel division, nurtured relationships with aerospace, defense and nuclear customers: Increased on-time delivery rate to more than 95%, and reduced product lead times by almost two weeks
- Maintained customer scorecard rating of between 90 and 100 for a six month period.
- Lead 2 cross-functional teams in PCC’s Zero Defect Risk reduction Plan: overseeing development of PFMEAs and Process Control Plans.
- Led quality engineering team in management and processing of return material requests–reducing RMA turn-around time by 25%.
- Led Quality team in submittal of AS9102 forms to customers following production move–helping project finish early and under-budget.
- Fulfilled duties of steel division Quality Manager and Quality Engineer.
Quality Assurance Technician
Star Cases, LLC dba Zero Manufacturing
03.2018 - 05.2019
- Lowest rate of return among inspectors during 15 month tenure.
- Championed implementation of inspection aids and defect Pareto charts: Reduced inspection time by 50%, Reduced rework rate by 25%.
- Quality liaison for source inspectors, supporting aerospace and defense customers.
- Program and operate Mitutoyo CMM.
- Perform inspections using hand tools.
- Perform First Articles per AS9102.
Quality Assurance Technician
DuraLine
10.2017 - 03.2018
- Oversaw testing of raw materials and finished product: increasing testing rate by more than 33%.
- Championed digitization of test results, calibration records, work instructions, and other documentation leading to more efficient quality organization.
- Perform in-process and final inspections.
- Identify, document and disposition non-conforming product.
Calibration Technician and Quality Control Inspector
Sierra Space
09.2016 - 08.2017
- Developed and implemented electronic log to track calibration cost and status of SNC’s 1000+ pieces of test and measurement equipment: leading to improved equipment tracking and decreased lead times.
- Led team in maintenance, management, and verification ESD control equipment.
- Held certification for IPC-J-STD-610 with space addendum certification.
- Performed source Inspections for various suppliers.
- Performed visual and dimensional inspections.
Quality Assurance Engineer
SEAKR Engineering, Inc
07.2008 - 04.2016
- Managed Quality Engineering duties for four programs in production and test while volunteering as sole Quality Engineering support for SEAKR’s manufacturing and test departments during second shift.
- Lead cross-functional Material Review Board (MRB) team for programs.
- Lead team in set-up, verification and maintenance of ESD control equipment.
- Company SME for Automated Optical Inspection (AOI) machine
- Authored training materials, developed and led training programs, authored, reviewed and updated standard operating procedures.
- Managed calibration program for measurement and test equipment.
Education
Bachelor of Arts - Liberal Arts And Sciences (History, Biblical Studies, Music)
Florida College
05.2008
Associate of Arts - General Studies
Florida College
Tampa05.2006
Skills
- ISO 9001/AS9100 compliance
- Critical Thinking
- Documentation Control
- Quality Management
- Product Inspection
- Corrective and Preventive Actions
- Team Collaboration
- Customer Service
- Quality Management Systems
- Customer Complaint Resolution
Certification
- Hexagon PC-DMIS for Vision 101–Hexagon Metrology CMM programming, 07/2023
- Crucial Conversations–Effective Communications Course–Vital Smarts, 09/2022
- Certified IPC Specialist for J-STD-001, IPC-A-610F & IPC-A-610 Including Space Addendum, 07/2017-07/2019
- Beginning and Intermediate GD&T Seminar, 05/2017
- NASA Certified Inspector for NASA STD 8739.1-8739.4, 2008-2016
Timeline
Director of Quality
Optisys, LLC
08.2020 - 03.2024
Quality Engineering Technician
PCC Structurals
06.2019 - 05.2020
Quality Assurance Technician
Star Cases, LLC dba Zero Manufacturing
03.2018 - 05.2019
Quality Assurance Technician
DuraLine
10.2017 - 03.2018
Calibration Technician and Quality Control Inspector
Sierra Space
09.2016 - 08.2017
Quality Assurance Engineer
SEAKR Engineering, Inc
07.2008 - 04.2016
Bachelor of Arts - Liberal Arts And Sciences (History, Biblical Studies, Music)
Florida College
Associate of Arts - General Studies
Florida College
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