Stephen Malvini Email & Phone Number

Santa Clara, Ca

- Manage Automotive Customer Quality Engineering and Global Customer Quality Manager teams.- Customers include major European/Asian Automotive Tier 1s and OEs with global supply chains.- Manage APQP programs for NPI customer acceptance and sustaining.- Customer quality contracts and DPPM agreements coordination.- Customer claims handling and failure analysis with 8D reporting.- Lead company to satisfy Automotive customer requirements and expectations.- Global contract manufacturer auditing to VDA6.3 requirements.- Monthly reporting of contract manufacturer and customer claims performance to company upper management.

Santa Clara, Ca

- APQP lead for new automotive module programs.- Quality management for existing programs and NPI to customer requirements.- Qualified main China contract manufacturer to major EU Tier 1 requirements for mass production.- Educate/guide company to meet Automotive customer requirements.Accomplishments/Certifications:- Certified TS16949 auditor

Santa Clara, Ca

Sr. Quality Engineer Responsible for quality engineering and quality assurance programs, including: incoming material quality, supplier development, process quality support, quality systems development, and customer complaint resolution. Accomplishments:• Leader, direct material discrepancy handling: improved timely processing of incidents, led activities to resolve top open issues, recovered $150k+ in materials previously held.• Assessment and adjustment of receiving inspection plans to maximize benefits using data.• Established traceability for complicated WIP materials to assure lineage to/from material and finished goods.• Quick reaction, containment, and resolution of part related issues in production.• Supplier site reviews for understanding of quality controls and follow-up on problem recurrence prevention actions/results.• Written procedures to document key quality business processes and responsibilities.• Established supplier ranking system to identify “at risk” suppliers for additional activities.• Deployed material specifications to newly qualified suppliers.

Quality Control Engineering Manager (2005 – July 2010)Led section of 25 engineers and assistant managers, responsible for component parts and completed vehicle quality for the Toyota Tacoma pickup truck. Daily task management responsibilities include problem solving of production issues related to supplied parts, vehicle system problems, parts change management, and clarification of completed vehicle shipping standards. Future model responsibilities include creation of new model project plans/targets, supplied parts development and inspection standards creation, change point management/risk assessment, clarification of change points, and regular reporting to executives. Other key activities for JD Power improvement, warranty reduction, and inspection equipment procurement and improvements for productivity gains. Deployed Toyota initiatives, Toyota business practices (TBP) and on-the-job development (OJD), to quality engineering staff to improve problem solving capabilities, team morale, and ownership of tasks.Accomplishments:• Successful 2009 Tacoma major model change implementation with relatively low experience engineering staff, simultaneous with 2009 Corolla major change program.• Quality control specialist hiring coordination to support 2009 model change staffing needs (hired 10+ engineers)• Inspection process and equipment improvements to meet 81 second cycle time target• Achieved company structural cost reduction targets of 2-5% annually• Achieved Toyota corporate shipping quality audit targets for last two Tacoma audits, including 0 defects in the last audit, the first time in company history.

Managed group of 5 quality control specialists for the functional parts responsibilities on the Toyota Tacoma truck. Special assignments during this period for passenger and truck line inspection equipment preparation, JD Power/IQS improvement coordination for the Tacoma, and overall regulation compliance coordination for the 2003 Toyota Voltz export to Japan market.Accomplishments: • Created engineering group dedicated to quality control inspection equipment management for increased focus and improvements• Established QC procedures system for documentation control and revision of key quality processes• Successfully passed MLIT (Ministry of Land, Infrastructure, and Transportation) regulation compliance audit for 2003 Toyota Voltz by Japanese government• Company leader for 2005 Tacoma JD Power improvements, introducing pre-production IQS assessment activities• Introduced non-contact alignment equipment with fully automatic toe setting for the 2005 Tacoma to improve ergonomic risk of manual adjustment and achieve alignment warranty reductions

Engineer responsible for quality of chassis supplied component parts and systems. Detailed duties included component parts supplier quality management, problem solving/resolution of line problems related to parts/systems, end of line and audit inspection equipment procurement and improvement, completed vehicle inspection planning, option check sheet creation/administration, JD Power improvement team for squeaks and rattles, warranty data analysis and activities to improve, and cost reductions.Accomplishments:• New model development of chassis parts for 1998 Toyota Corolla and Chevy Prizm• Created inspection option check sheet for passenger and truck lines, later trained and handed-off to inspection group• Implemented cost reduction for elimination of Corolla steering wheel damper ($750,000 annual savings)