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, improved procedures and adherence, and implemented fail-safe in order-management systems. Led quality improvement on low yield products resulting in improved manufacturability, increased sales, reduced customer complaints and warranty repairs, improved manufacturing flow and on-time delivery. Implemented SharePoint for managing customer concerns allowing collaboration for response and follow-up with corrective and preventive actions (CAPA). Established root-cause tracking to identify improvement opportunities in product, process, and customer satisfaction. Managed CAPA on wide range of customer concerns including manufacturing defects, supplier quality, design, and government compliance

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 flexible film.• 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 change management.• 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.• Investigated and responded to out-of-spec conditions and customer complaints.• Participated in selection interviewing for seven QC technicians and an engineer.• Participated in gate-controlled design and development processes and record keeping.

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. • Produced quarterly QMS management reviews, associated corrective action plans, and verification of closure. • Managed quality data tracking and analysis for waste, customer complaints, supplier accommodations, non-conforming product disposition, and corrective and preventive actions.

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, UK, France, and Canada. Managed Rochester QC lab team with improved test system control and productivity.• 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%. • Achieved ISO9001:2000 registration with zero non-compliance findings during two registrar audits.• Led independent internal audits for ISO 9001 and cGMP quality systems. Complied with requirements of Good Manufacturing Practices 21 CFR PART 820 for x-ray, cardiographic, and endoscopic recording films.

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.