Dennis Foley Email and Phone Number

With over 7 years at Apple and previous roles as Global Quality Director at Boston-Power and PolyStor, I offer expert consultation as a seasoned lithium-ion battery specialist. At Apple, I led the establishment and management of the lithium-ion battery engineering quality, analytics, and supplier compliance department, overseeing a team of 20 engineers and a $1.5M budget. I specialize in:1. Battery Engineering Quality and Analytics: Developing statistical models and machine learning algorithms to enhance performance and reliability, addressing issues like capacity fade and swelling.2. Supplier Compliance Management: Creating robust compliance frameworks, conducting audits, and implementing vendor self-qualification systems.3. Quality Assurance and Risk Mitigation: Designing anomaly detection systems and firmware upgrades to ensure product reliability and mitigate risks.4. Statistical Process Improvement: Applying advanced statistical techniques to optimize processes, reduce defects, and develop qualification protocols.5. Innovation and Continuous Improvement: Collaborating with clients to drive innovation in battery design and manufacturing, ensuring sustained competitiveness.With a legacy of leadership and innovation, I empower organizations to navigate challenges and excel in design and manufacturing.

-Established a new lithium ion battery engineering quality, analytics, and supplier compliance department over 7 years to improve design and manufacturing quality with 20 engineers and $1.5M annual budget-Developed a vendor quality system audit plan and conducted audits for all Asian battery manufacturers.-Played a key role as battery quality manager in resolving critical unintended power off (UPO) issues on ---iPhone 6s caused by poor quality batteries.-Created a compliance engineering team of 5 members to conduct monthly audits of supplier compliance as directed by the Senior VP. Team completed 25 in-region supplier audits yearly with multiple compliance alerts that were resolved by vendors and Apple supplier engineering.-Created an analytics team consisting of 10 data scientists to utilize machine learning for modeling swell, capacity, and impedance. Resolved critical MacBook swell issues among other iPhone, iPad, Apple Watch, and AirPod quality issues with machine learning math models.-Led in-situ device qualification of batteries for all commercial platforms with up to date customer use cases to ensure new releases met varied customer requirements.-Implemented advanced statistical Maccor sampling to meet Apple's required confidence and DPPM (Defects Per Million) for impedance, capacity, and swelling.-Developed a vendor self-qualification system similar to automotive PPAP (Production Part Approval Process).-Reduced reliance on dual vendor/Cupertino Maccor testing and minimized cycling channel requirements through the vendor self-qualification system.-Through modeling, statistics, and vendor self-qualification, achieved an annual reduction of over $2 million in Maccor requirements.- Developed anomaly detection system with customer shared data so issues like capacity fade could be resolved with FW upgrades. -Retired at 62 to pursue relaxation and occasional consulting with my company Advanced Statistics for Design and Manufacturing.

Authority and responsibility to resolve all matters pertaining to quality. Lead continuous improvement prevention and Six Sigma, initiatives. • Lead Quality Department for Boston-Power including 350K square foot Li Ion manufacturing facility in Jiangsu China and Beijing/US R&D centers• Achieve TS16949 certification. Manage APQP and Stage Gate process quality to ensure customer satisfaction at NPI shipment.• Lead new factory Process Qualification including TPY, SPC, and process capability improvements and auditing to world class standards.• Drive customer satisfaction with 8D root cause/corrective action reports and internally manage with Key Process Indicators (KPI's) using Agile PLM & SharePoint company-wide.• Manage Document Control process via Agile PLM to ensure ECO's are accurately processed• Manage safety testing to ensure UL, UN and customer approval and certification• Extensive international experience in China including design, supplier, and manufacturing quality leadership.

• Resolved quality issues on Joint Air-to-Surface Standoff Missile (JASSM) program by implementing a metric-management system, identifying and resolving true root causes, and improving SPC process capability. Efforts resulted in Lockheed Martin (ITT Walpole’s largest customer) awarding ITT Walpole its 2007 Supplier of the Year award. This resulted in preferred supplier status for future contracts.• Implemented inspection Lean one piece flow with standard work times, Kan Ban bins, and installed highly factory visible “emergency” red light if daily output would not meet plan. Project resulted in faster quality feedback to production, predictable OTD shipments, and significantly lower inspection costs.• Maintained AS9100/ISO 9100 Quality System and served as management representative. Hosted customer and third-party audits with minimal findings and negligible business disruption. Achieved Bell Helicopter Flight Safety supplier certification and National Aerospace and Defense Contractors Accreditation Program (NADCAP) certification, allowing ITT to win contracts and build composite hardware for Bell Helicopters and GEnx engines. • Managed 4-6 Lean manufacturing events per year by leading employee teams through Kaizens which eliminated non-value added activity. As local Black Belt, delivered $250K Kaizen and other continuous improvement annual savings. Certified 12 Six Sigma Green Belts from 2006-2009 with over $300K in Green Belt project savings

• Instituted supplier quality improvement program that improved supplier rolled throughput yield from 80% to 90%, increased Lucent function tester yield from 92% to 97%, and reduced product failure upon delivery from 0.5% to 0.1%. This work ultimately achieving a significant improvement in customer satisfaction.• Trained 50 Lucent and supplier engineers in basic Six Sigma methods (Define, Measure, Analyze, Improve, Control) as supporting action for supplier quality improvement program.• Management representative for TL9000 and UL compliance with no significant audit findings.

PolyStor was a pre-IPO start-up battery company with about 60 employees focusing on the lithium ion battery market for cell phones and next generation vehicles. The founders and technology originated at Lawrence Livermore Labs.• Developed and implemented Quality department from the ground up, including Battery Test Lab (UL/UN), Receiving Inspection (with Lab), In-process Inspection, Final Inspection, and ISO 9001 Quality System.• Achieved Motorola qualification which contributed to PolyStor becoming a qualified lithium ion prismatic battery supplier to Motorola.• Worked with design engineering and R&D to plan and execute over 20 designed experiments (DOE’s) to optimize longest lasting cell phone battery in the world. Experiments improved battery leakage, cycle life and UL safety as well as production uptime.• Trained 20 Six Sigma Green Belts in the use of applied statistics to design and manufacture new products.

Process Engineer, plating, reverse osmosis, QE, Six Simga, SPC, GRR, DOE, APQP Manager