Jon Walls Email and Phone Number

I managed the activities of a 12 member (Salary and Hourly) Quality Engineering and program management department including department planning and monthly plant KPI reporting to executive management. Core is a three shift union operation focused on the batch manufacturing of sheet molding compound (SMC), molded products and bonded assemblies for various markets including medium and heavy-duty truck, marine, automotive and other industrial products. PPM KPI, Process Auditing, APQP and new model program management responsibility as well as customer relationship improvement and production process improvements.Internal TS-16949 auditor.

I managed the activities of a 20 member Production Engineering and Facilities Maintenance Department including department planning and monthly KPI reporting to executive management. Planning and execution of expense and capital budgets completing five straight fiscal years under budget.Responsible for complete automotive electronics manufacturing plans, mass production preparation and launch activities including process design, line layouts, jig and fixture development, work instructions, PFMEA / control plan process and labor cost calculations.Saved $700,000 by leading 3 year materials cost down project including localization of parts, vendor negotiation and reliability testing for new parts.Reduced labor costs by $240,000 / year through cycle time reductions, line layout improvements and fixture consolidation.Created company energy reduction team resulting in $10,000 / year in electricity savings.Reduced process defects on flagship line by 20% through data driven kaizen activities.Designed a macro-driven excel work order priority management system resulting in improved on-time work order completion.

Responsible for complete manufacturing plans, mass production preparation and launch activities of OEM electronics including line layout, jig and fixture design/development, standardized work instructions, PFMEA /control plan and labor cost calculations.

Responsible for the daily activities of 6 molding technicians and 90 hourly employees focused on interior and exterior plastic products supplied to automotive manufacturers Tier 1 (GM, Chrysler) and Tier 2.Assisted in launching more than 20 new programs in less than 1 year by monitoring and eliminating quality issues, training and coaching operators, improving work cell layouts and process flows.Conducted weekly meetings in areas of safety, quality, scrap reduction, and dept goals.Assisted in the implementation of a Lean Manufacturing Program including ­Kaizen activities, JIT, Kanban system and 5S.Wrote standardized new employee training program.2nd shift Emergency Response Coordinator ­ Responsible for emergency issues in entire plant on 2nd shift.