robert patterson

Lead the product realization process using Customer Voice Analysis, Brainstorming-Concept Generation, QFD (4 Levels), DFMEA, PFMEA, DVP&R, Standards, Product Modelling, Process Modeling. Led the Product Realization Process for 16 new models of refrigerator drawer systems by using Voice of the Customer to Prioritize Product requirements. Led the Product Realization Process for the design and release of a Modular Motorcycle Shipping System used for 26 separate vehicle platforms over a 3 month period with total project planned savings of $10Million.

Liaison for precision ground components supplier to end client to ensure timely resolution of quality complaints including verification, initiate interim solution, communication of root cause and permanent corrective actions. Reduced the percentage of invalid complaints from 60% to 10% through review of contract, specification and measurement method. Containment of issues occurs in less than 24 hours.

* Lead a cross functional team transferring 250 fixtures and 900-part numbers to a new startup manufacturing facility. Review Historical data, identify systemic issues, recommend and initiate corrective actions without delaying the planned decommissioning of the current facility. * Established standard analysis method and trained a team of 9 Quality Engineers * Implemented standardized process changes eliminating 92% of historic defects * Reduced prove out time from 18 days to 3 days per part. * Managed team to stay ahead of schedule for decommissioning resulting in significant cost avoidance realized by being on time.

* Collaborate with Suppliers and Product teams to reduce the total product cost of 132 Burn to Shape part numbers. Perform should-cost modeling and provide to buyer for negotiation of new prices with all North American Suppliers. * Reviewed global benchmarking study and established the target price level 600% lower than current. * Developed a process using Hypertherm Pro Nest software and created scripts to maximize efficiency from 30% to 70% and increase velocity from an average of 300 Feet per hour to 1300 Feet per hour. * Performed process model to establish target price for complete sequence of 8 complete vehicles consisting of 1056 parts per shift. * Achieved a cost reduction from $3 / kg to $.62 / kg with estimated savings over 5-year period of $10Million

Lead the Advanced Product Quality Planning team from Voice of the Customer to Part level requirements. Use Teamcenter Systems Engineering software to review and document requirements. Perform QFD Level 1 and 2 for the finished platform and sub-systems. Finished Platform level requirements, and competitive assessment completed Crowd, Swing, Lift, Dump, and Propel systems completed to the part level

Lead a team to implement APQP for hydraulic steering, brake, cooling, implement, propulsion systems and components that are subject to redesign due to Tier IV emissions requirements. Review NPI team activities and ensure that risk level is understood and provide assessment of APQP compliance for one hundred eight two vehicle platform changes.

Provide Quality Assurance support for New Machining Center complex. Identify New Machine Qualification Requirements. Qualify totally automated line and assembly/test process. Perform DFMEA, PFMEA, and Control Plans. Establish a test machine database and provide reports to management for machine utilization while managing the prioritized problem list. Facilitate Structured Problem solving teams as necessary

Scope and develop three to five 6 Sigma projects as well as providing green belt and yellow belt training.

* Manage all QS9000 requirements for elements 4.2 Quality System, 4.5 Document Control, 4.14 Corrective and Preventive Action, 4.16 Records, and 4.20 Statistical Methods by documenting * What * When * Who * How * and * Where * objective evidence. Develop strategy for implementation of ISO/TS 16949. Manage systems administration of Pilgrim Q&MIS and Automotive focus modules.

Manage Product Test Services area expenses and budget. Provide field failure analysis, outgoing performance/endurance audits, and fuel system master certification. Provide training to department personnel. Facilitate 8D and Multidisciplinary teams. Provide feedback to dealer and engine facility personnel on warranty claims. Maintain plant problem list, issue corrective action requests. Maintain NIST traceability on all department test/and measurement systems. Achieve and assure QS9000 compliance through the administration of internal audits.

* Assure the quality of outgoing fuel systems and initiate corrective actions to product groups for field failures. * Procured test equipment for both performance and endurance testing. * Qualified test machines and achieved traceability to NIST with the lowest level of measurement error in the corporation. * Transferred product development * Zero * from tech center to newly commissioned machines. * Set up random sample of field failures for each of five separate product lines. * Provided warranty apportionment by department for monthly improvement plans