Dean Holle Email & Phone Number

Manage engine compartment tool procurement, engineering and launch for a tier one automotive supplier of interior carpet, head liners, and acoustic and thermal barriers with six facilities in the USA and Mexico.► Quoting - Respond to up to 40 customer queries per month with engineered tool lineups, cost quotes and timelines. Maintain a 100% record of completing all quotes within 5 days.► Standards - Manage tool design phase, and design requirements for compression molds, shear by-pass trim dies, water jet trim systems, poka-yoke and check fixtures for high volume engine compartment, RIM and Damplex production.► Project Management - Identify suppliers, negotiate contracts, and coordinate tool construction and validation trials► Improvement – Drive cost and quality improvements for existing tooling. Implemented design standard updates which entirely eliminated what had been the top two failure modes for new compression molds.

Contract liaison between the R&D group and manufacturing operations at FHP/O Cedar, a $1 billion global housewares company. Principle responsibilities included the identification of product design and production process inefficiencies and problem areas, then development and implementation of solutions.► Cost Reduction - Identified key changes to reduce material cost 7%, increase recycled material content, improve throughput over 15% and improve fiber quality for the monofilament bristle extrusion line. Made $800 tool fix to eliminate assembly interferences which reduced worker clinic costs over $36K annually.► Capital Equipment - Delivered full featured tool sourcing program to assure better part production and quality performance while reducing tool cost and lead time.► Quality Improvement – Identified the most significant chronic field complaints, and resolved them. After four month lag-to-market, call volume dropped at least 6% per month for three months.► Product Development - Supported gated product life cycle program to gain better control of NPD projects and reduce product end-of-life costs. Recommended several product line changes to improve manufacturability and COGS while also setting up a more coherent good-better-best strategy. Designed universal broom block receiver which simplifies tooling, speeds cycle time, and accepts a variety of handles regardless of thread type.► Other Initiatives - Designed and implemented new user friendly product specifications to clearly define and communicate requirements, test methods, acceptance criteria and the associated quality plan.

Managed QA for two divisions of a global OEM office product firm, including up to 3400 SKUs, 80 suppliers, 21 countries, and 20 product launches per month.► Product Safety - Worked with Underwriters Laboratories, Consumer Products Safety Commission, and legal counsel to reduce product liabilities. Deep involvement in regulatory affairs. Established and managed full document control program.► Plastics Expertise - Acted as manufacturing and plastics technical resource to suppliers and internal product development groups. Frequently helped molders solve process problems they could not solve. Implemented restricted substance, supplier code-of-conduct, APQP, PPAP, and routine reporting.► Supplier Improvement - Advised nearly 200 factories on process simplification and improvement, cost and lead time reduction, and quality enhancement using ISO9000, GMP, lean, six sigma and other techniques.► Supply Chain Quality Control - Established Hong Kong and Changzhou offices to monitor suppliers, drive CARs, and conduct on-site OGI inspections throughout Asia. Reduced QC costs in Asia by 70%. Maintained field complaint, operating budget, return rate and critical event rates substantially below industry norm while also keeping QA/QC headcount and costs to an absolute minimum. Managed corporate document control program.

Managed engineering, maintenance, tool room, and QA in a captive injection molding operation with 23 presses (80 to 700 tons). ► Cost Reduction - Improved machine utilization 19% and reduced scrap 5% by driving process documentation, mold change SOPs, and conducting technician training. This, combined with the implementation of a 24/7 work schedule and a cellular manufacturing focus, produced over $3.6 million in previously unrealized capacity with almost no capital outlays. Reduced operating costs by at least $1 million per year for four consecutive years.► Tool Procurement - Performed global corporate tool procurement for up to 80 injection molds per year, from part review through quoting, negotiation of the purchase contract, tool debug, US customs, delivery and full production validation. Developed tool design standard and supplier base to substantially reduce tool lead-time and costs while improving end-process robustness and part quality. ► Scheduling and KPIs - Managed a real time shop floor monitoring system (OPM20) and developed a program for tracking key performance indicators. Performed forecasting and scheduling. Wrote software to optimize the assignment of jobs to machines best suited to run them.► Capital Equipment - Conceived, justified, procured, installed and trained users on 73 capital equipment projects (e.g. robots, chillers, facility upgrades, and IMMs) and completed all on time and under budget.► Process Improvement - Supervised six-man maintenance crew. Created parts crib and implemented work hours and parts crib management software (MP2). Built a full function QA program, with a lab, procedures, and a trained 24/7 staff. Introduced a BBS system to proactively reduce safety risks in the manufacturing area. Reduced annual lost time incidences by 65% by the second year.

► Principal technical resource with complete authority to implement changes in tools, processes, and documentation to reduce waste, control cost, improve quality and safety, etcetera.

► Wrote corporate quality manual consistent with ANSI/ASQC Q-94 1987 (ISO-9000) and GMP (21CFR820) to support UL, medical, military, and automotive customers. Implemented SPC, FMEA, APQP, and PPAP and many other capabilities, contributing significantly toward corporate attainment of ISO & QS certification.

► Responsible for worker safety, scheduling presses, capacity planning, machine utilization, equipment purchases, and product quality. Implemented cell manufacturing concept, process documentation, cross-functional cost reduction teams, and employee training program.

Mechanical Production Technology Curriculum

► Additional coursework through the ASQ. 25 year “Senior Member” and contributing author to the ASQ. ► More than 80 additional seminars.

Sqci, Sqcii, Quality Control Management & Mgmt Accounting For Quality Certificates

Maintenance Certificate

Investment Certificate

Quality Engineering Certificate