Josh Malone Email & Phone Number

Dora, Al, Us

Evansville, In, Us

Evansville, In, Us

South Hackensack, Nj, Us

Tiffin, Ohio, Us

Develop quality systems and processes to control the quality of new products and new manufacturing processes. Includes specification development, tolerance development and the associated metrology methods to insure quality products. Design tooling for specialized test methods. Conduct Failure Mode Effect Analysis (FMEA) and develop the associated control point specifications and gauging. Perform Advanced Product Quality Planning (APQP). Optimize Supplier Quality Assurance (SQA) program for all suppliers of products, raw materials and services. Ability to conduct external system audits and work with the suppliers on Continuous Improvement to improve the processes. Visit suppliers annually to ensure compliance with standards. Implement and train associates in Statistical Process Control through WinSPC data collection (manual and automated).

Tiffin, Ohio, Us

Manufacturing operations include film extrusions and conversion of LDPE of both can liners and food bags and LDPE pelletizers. Oversee all elements of plant quality they relate to product, process capability, logistics, training, quality systems, and measurement & analysis. Select, implement and train employees on a real-time data acquisition and statistical analysis software package. Supervise 4 Quality Supervisors and 24 QA Inspectors between 2 production facilities and additional Inspectors at Webster Logistics warehouses. Direct company complaints to suppliers through proper corrective actions to include temporary and permanent measures. Lead GMP (Good Manufacturing Practices) effort. Received Excellent rating from third party auditor, ASI. Train on and enforce GMP procedures with all associates, multiple plants' appearance, machine maintenance, etc. Maintain working relationship with third-party test labs for comparative analysis of product versus NBE (national-brand equivalent). Conduct GR&R studies to validate test equipment to include a tensile tester, an FTIR, an auto-gauger, tear testers, a moisture analyzer, a melt indexer, and other assorted gages. Responsible for creation of quality methods and requirements for new product development. Design and write MS Access databases for competitive analysis comparison and product caseweight/poundflow analysis.

Maintain certification of TS16949 during multiple TS surveillance audits by BSI. Responsible for quality of over 30 products to many Tier 1 and Tier 2 automotive suppliers. Manufacturing operations include stamping, welding, injection/insert molding, and header connector stitching. Primary window to customers and suppliers. Set up customer claim evaluation system that reduces response time by up to 50%. Champion 8D and 5-why problem solving teams. Oversee Quality metrology lab. Write inspection programs for Mitutoyo QV302 CMM with microscope and touch-probe with QS Pac software. Supervise 3 Quality Engineers, 1 Lab Supervisor, 5 Quality Analysts, and 3 Quality Auditors. Report to the plant manager and company president on a daily basis. Present monthly Quality meeting to include departmental metrics, internal and external corrective action reports, scrap report, and loss-reduction programs. Implemented internal non-conforming material team to disposition yellow-tagged items immediately. Monitor and evaluate employee effectiveness/progress. Effectively communicate with parent-company in Japan to relate and resolve Quality issues. Create robust inspection standards for incoming & outgoing products. Responsible for all updates and distribution of Quality controlled documents. Launched 5S program that has reduced customer-visit visual complaints to zero. Used value-stream mapping to counsel on production layout during building expansion. Established internal training program for product inspection which decreased customer complaints by 25%. Involved with new product development teams.

Work towards certification of TS16949 in a Tier 1 automotive environment. Responsible for quality of multiple products, which includes injection molded parts, HVAC systems, and automotive front end modules. Experience in a just-in-time (JIT) assembly environment and batch assembly. Assist in new product launches, error-proofing assembly lines, and training associates. Create auditor and inspector worksheets for daily use. Create MS Access Document Control Database. Familiar with some aspects of SAP. Oversee and maintain 4M supplier, internal, and customer process change requests. Champion 8D problem solving projects. Implement immediate reaction/containment plans for customer issues and produce proactive countermeasures to eliminate problem issues. Prevent defective parts from delivery to customer through effective poka-yoke methods. Counter problematic areas by improving high RPN operations. Experience with 5-star audit process. Create and sustain warranty database to hold suppliers accountable and reclaim cost of field claims. Communicate with international suppliers of automotive parts. Experience with organization through 5S activities.

Working knowledge of TS16949 and ISO Environmental Quality systems & auditing. Responsible for supporting all elements of the supplier quality program and supervising the inspection staff. Focus on custom material and OEM products. Responsible for initial supplier survey/ qualification, working with R&D, Supply Chain and all other groups in requirements definition and introduction of new products/suppliers. Work with suppliers on root cause/corrective action. Effectively communicate with international chemical suppliers. Assure the complete definition and communication of all product performance and test requirements and the methodology for verifying conformance by the supplier. Identify risk areas and where appropriate add inspection/test requirements upon receipt. Develop and implement Part Control Plans. Establish/validate supplier process controls, use of statistical techniques and conformance reporting requirements to minimize the need for redundant verifications. Experience with new product launches, product/process validation, and PPAP approvals. Demonstrated accomplishment of tangible results - PPM reduction, cost savings, scrap/rework reduction, successful new launches, etc. Demonstrated application of SPC, FMEA, control plan, measurement system analysis, error proofing, capability studies, blueprint GD&T, root cause analysis & problem solving tools. Supervised Metrology Lab including 2 Receiving Inspectors and 1 PPAP Validation Specialist. Metrology equipment included a CMM, a Contracer, Calipers, etc.

Supervised various teams of employees in Quality Department and Receiving Line Inspection. Set up manufacturing line and develop and implement tooling to operate processed parts. Administered and actively used digital photography, high-speed video, Differential Scanning Calorimeter and FTIR. Performed equipment calibrations, ballistic testing, moisture and effluent analysis and weld seam analysis. Wrote and published procedures on multiple pieces of equipment and machinery and trained other associates how to operate and use effectively. Thorough knowledge of helium/Radiflo leak detection systems. Experience and familiarity with QS9000 and ISO14000 quality and environmental policies. Wired electrical relays into data acquisition system. Created and put into practice standard forms for various testing and equipment standardization and calibration used throughout corporate day-to-day operations. Daily use of high precision measuring devices such as micrometers and calipers. Knowledge of CNC-based microscopy. Purchased materials to effectively and efficiently run the chemistry lab.

Master'S Degree, Chemical Engineering

Bachelor'S Degree, Chemistry

Chemistry