Blair Downs Email & Phone Number

Covington, Virginia, United States

Responsibilities: Responsible for managing and leading both quality and continuous improvement aspects for the plant including, but not limited to quality inspection and control, quality assurance and calibration, continuous improvement, problem solving, and maintaining certifications, including ISO 9001, IATF 16949, RC14001, Kosher, and Halal. Part of the plant staff for the site and a key contributor to setting and executing the vision for the next 3-5 years. Well experienced at lean sigma, Kaizen, 5S, 8D, Fishbone, MSA, defect containment and reduction, customer response, operations support, data analysis, SPC, calibrations, and strategic planning.Key Accomplishments:• Reduction in number of annual customer complaints from 17 to 4 within first 3 years. Achieved plant low of only 2 complaints in 2023.• Launched continuous improvement program at the Covington site which included training of >75% of the employees, supporting and mentoring Green Belt candidates, developing idea generation and tracking system, facilitating diagnostic and Kaizen events, establishment of KPI scorecard and GEMBA walk, and influencing plant management on how to run CI in the plant. • Establishment of 8D process and use of root case analysis (RCA) tools like 5 Why, Fishbone, Human Error, etc.• Simplification of QMS/EMS systems while reducing the severity and number of external audit findings. • Development of internal audit, management review, and CAPA processes to improve effectiveness.• Improvement of gage calibration system and establishment of gage traceability and record keeping system.• Development and improvement in MSA (GRR) system to reduce non-value-added testing while improving the reliability and impact of value-added tests.• Establishment of plant scorecard and improved KPI trending.• Leading, coaching, and mentoring QA and other personnel to establish stronger teamwork, improved employee ownership and pride, and better salary/hourly (union) relationships.

Berea, Ky

Responsibilities: Managing 3 direct hourly and 1 non-exempt. Management Representative and maintains both ISO 9001 (QMS) and 14001 (EMS). Manages quality, warranty, and testing objectives for site. Maintains and improves performance and safety within the dept. Handles quality issues from supplier, customer, and internal perspectives. Facilitates operations, engineering, etc. in day-to-day activities. Develops skill levels and expertise of the engineers and technicians. Key Accomplishments:• Supported launch of continuous improvement program (EMLS) at the Berea facility which included facilitating Kaizen events, mentoring and coaching Green Belt candidates, and developing a 3-5 year strategic site plan.• Supported relocation of brake adjuster process into Berea facility. Lead capability, receiving inspection, warranty, and quality control aspects. Reduced non-value added work in 2 areas by 60-70% within 1 year. • Lead revamp of quality controls during hubcap relocation to Berea and used SPC data to achieve ~76% reduction in the clutch rebuild frequency. • Supported project to install an automatic 100% inline gage for CentriFuse in order to achieve acceptable gage R&R results for customer specific drum, as well as improvements in safety, ergonomics, and productivity.• Supported Rome plant manager in the evaluation and gap analysis of the quality systems in the facility.• Facilitation of Kaizen team that developed AERIS Axle Prep Cell. Awarded President’s Award for Operational Excellence.• Facilitator for APQP process for the brake drum and brake adjuster product lines.• Lowered plant’s customer complaint PPM to < 35 over a 2-year period.• Lead environmental activities at the plant in the absence of an on-site, including monthly EHS reporting, storm water reporting, SARA Tier II, and Form R reporting for 2015. Awarded President’s for Environmental Excellence for supporting 96% reduction of HAPs due to change in paint formulation.

Verona, Va

Responsibilities: Managing 2 direct hourly employees. Management Representative for ISO 13485 and responsible for addressing audit non-conformances. Maintain QMS at the company with particular focus on medical device compliance for FDA, Health Canada, and Europe (MDD). Managed customer complaints and defects. Key Accomplishments:• Training completed in ISO 13485, ISO 14971, and FDA 21 CFR 820.• Implementation of 8D method for addressing minor non-conformances and internal quality issues.• Introduced engineers to concepts of MSA and Gage R&R to provide better measurement equipment results.• Utilization of technical and collaboration skills to investigate, respond, and close out customer concerns.

Longview, Tx

Responsibilities: Managing 5 direct hourly, 2 indirect, 3 non-exempt employees. Management Representative for ISO/TS16949:2009. Maintain QMS at the company and safety within the dept. Handle quality issues from supplier, customer, and internal perspectives. Facilitate operations, engineering, etc. in day-to-day activities. Develop skills levels and expertise of the quality engineers and technicians. Maintain spending on a ~$750K budget.Key Accomplishments:• Identified 76 areas of improvement for QA, initiating corrective action on 32% of them within 1st yr. • Established metric to reduce customer corrective action response time from > 6 mon. to < 3 mon.• Streamlined receiving inspection activities: 2→1 techs; 24→3 wks for defective product disposition.• Drove for reduction in calibration checks by 15-20% through removal of non-value added checks.• Transitioned warehouse audits upstream in the process: quality impact ↑, customer issues ↓.• Facilitated retirement and replacement of 4 direct reports within the department.

Longview, Tx

Responsibilities: Kept projects on track for product performance, cost, and milestones. Addressed customer questions & concerns, warranty & field issues, and OEM installation problems. Provided manufacturing and quality support. Worked with vendors to establish specifications and performance goals. Managed Co-Op program. Key Accomplishments:• Design engineer & facilitator for project to reduce Voyager seal from 3 pc to 2 pc (Endeavor) Aug ’07 – Sep ‘09. - Annual cost savings for project after completion was ~$750K - 3 potential U.S. patents submitted from research and development during project. - Awarded President’s Award in Innovation Excellence from Corporate (EnPro Industries).• Implemented use of statistical tools for testing to obtain effective, accurate, and efficient results. • Developed new methods for testing and utilized FEA to reduce development cycle time and prototyping.

Greenville, Sc

North American Industrialization Leader for PAX (60% time): Industrialized and qualified process for the PAX extended mobility tire (new product) at Columbia, SC production plant. Liaison and Manufacturing Representative for Tire Development shop (40% time): Resolved issues between shop and central development.Key Accomplishments:• Instrumental in leading efforts to reduce internal PAX scrap at plant from 30% to 5% in ~ 3 months.• Project lead to develop and qualify development shop machine that cost less than production equivalent.

Greenville, Sc

Responsibilities: Utilized design tools and experience to obtain robust, high quality tires for OEMs. Converted customer parameters for a specific vehicle into a manufacturable product. Addressed manufacturing issues.Key Accomplishments:• Selected as first design engineer to establish new OGEP Usine role at Ardmore, OK facility.• Initiated Kaizen efforts to correct 52 modes of failure in concept to industrialization design process.• Designed OE fitments for GMC Envoy / Oldsmobile Bravada and GM Utility truck.• Selected as design engineer to facilitate transfer of BMW X5 OE fitment from Europe to Canada.• Selected as key user for parametric CAD software based on skill and expertise with tool.

Richmond, Virginia, United States

Key Accomplishments:• Developed supersonic draw jet nozzle for new manufacturing process through CFD and lab testing.• Researched recycled PET and hot-stage microscopy for development improvements for Tyvek®.

Masters Of Engineering, Engineering Management

Bachelor'S Of Science, Aerospace And Ocean Engineering