Dan Sapper Email & Phone Number

Rochester, New York, United States

Retired - open to consulting and short contracts

Rochester, New York Area

Implemented new strategy for Quality Engineering support of Programs and Sales Teams supporting United States Department of Defense and allied customers. Led Six Sigma Black Belt project teams to improve fulfillment of customer orders, from contractual requirements through product shipment. Reduced incidents of nonconformance in government inspections.

Rochester, New York Area

• Designed strategy and implemented quality assurance in a start-up business for development, commercialization, and manufacturing of Touch Screen Sensors by flexographic printing and plating micro-electronics on.
• Established ISO 9001 Quality Management System resulting in readiness for certification.
• Implemented manufacturing quality assurance including product specifications, control of nonconforming product, document and data control, quality records, corrective and preventive action systems, risk assessment and.
• Assessed customer quality requirements, investigated and procured test equipment, devised and documented test methods.
• Established four QC laboratories, calibration control systems, and inspection standards.
• Set up QC schedules and product sampling. Linked measurement equipment to SPC and genealogy systems. Automated the QC systems to hold product after transformation steps and release it with conforming test results.

Rochester, New York Area

• Managed division and department quality systems, continuous improvement, and quality reporting for manufacturing areas of Coating, Melting, and Quality Control.
• Achieved ISO 9001 certification using visual controls, confirmation checks, documentation and data control, corrective action systems, quality records, and external audits.
• Managed manufacturing quality incidents for containment, communication, root-cause analysis, corrective and preventive actions and systems for change management.
• Led QC laboratories for production and development testing of silver halide photographic emulsions.
• Supported “Morning Markets” in several departments, driving escalation for testing and disposition of nonconforming product resulting in minimized impact to customers.
• Conducted formal analytical troubleshooting sessions to resolve production crisis or line-stop situations.

Rochester, New York Area

• Worldwide technical leader for production and development testing of silver halide photographic emulsions.
• Managed proprietary testing equipment, upgrades, and technology transfer for subsystems of coaters, optical exposing, chemical processors, fiber-optic densitometers, software, and supplies used by plants in USA, China.
• Led international team to accredit new suppliers, transportation, stock-keeping and SAP for consumables.
• Improved product first pass yield (FPY) by 75% in conjunction with Emulsion Manufacturing Department.
• Devised and validated new analytical test methods and improved testing processes, resulting in improved FPY.

Rochester, New York Area

• Led quality improvement for Melt/Coat Division (1200 people).
• Reduced quality incident waste by 68% in a single year.
• Implemented mistake-proof/fail-safe (MP/FS) for 84% of quality incidents.
• Led cross functional teams in FMEA and MP/FS sessions, resulting in fewer and less severe incidents.
• Implemented and led KOS Morning Market, resulting in rapid resolution of quality problems.
• Improved FPY by 12% each year. Reduced wide roll discards by 25%.

Rochester, New York Area

• Led organization's initiative to create a “Winning and Inclusive Culture.”
• Designed, implemented, and taught inclusion, diversity, and personal empowerment.
• Led team of nine cultural excellence leaders throughout an organization of 3300 people in four divisions.
• Assisted design and implementation of mentoring program for entire manufacturing plant.Skills: Change Agent, Leadership of People, Inclusion & Diversity, Mentoring, and Coaching.

Bs, Paper Science & Engineering, 3.5

Activities and Societies: Student SenateEngineering concentration in Process Control

Certificate, Executive Education Leadership Institue

Five day leadership institute for executives and high-potential emerging leaders. Coursework included: > Leadership: Leadership Theory.