Stephen Sellers

Work History

Work History
Oct 2008 - Dec 2008

Supplier Quality Manager: Electrical

Promoted to provide leadership and strategic direction for advanced supplier quality activities, such

as AQP, PSO, PDR, PPAP, FMEA, PV Testing and Control Plans for truck and car platform overhead

and interior lighting.  Directed supplier qualification and development, along with corrective

action reporting to assure completeness and resolution of supplier quality and capacity issues. 

Served as a Subject Matter Expert (SME), for the supply base on process continuous improvement

projects in an attempt to improve components and increase quality.Resolved pre-launch and post-

launch conflicts between assembly plants and suppliers.

  • Dramatically reduced warranty liability costs and exposure by resolving electrical quality issues in plant in 2 plants due to a lack of consistency in the supplier’s processing.
  • Resolved chronic, 10-year engineering stack up issue experienced across multiple product lines in 3 major domestic and international plants that was previously addressed by multiple engineering teams. 
Nov 2004 - Oct 2008

Program Manager & Senior Vehicle Quality Specialist

Directed the advance quality planning (APQP, Control Plans, PFMEA, PV Testing, PPAP, Continuous

Improvement, SPC, Pareto Analysis, Historgrams, 5S, and PSO) and management of NPI and

carryover truck programs, and all supplier quality issues between the company and Global Sourcing

organizations.Served as the executive level representative during the marketing and strategy

meetings for the product team. Led the supplier quality team on pilot build issues during the product

development cycle through vehicle launch and resolution of all issues for Root Cause and Corrective

Actions across all commodity areas (BIW, Interior, Chassis, Electrical, and Powertrain). As a

member of the Change Notice Approval committee, evaluated engineering changes for accuracy,

completeness, and necessity.Managed 2 direct reports.

·Set a new organization-wide benchmark by directing all quality initiatives on a high-profile 

    product in 2008 that re-entered the commercial market with 0 unresolved supplier quality related

    issues. Successful product earned high reviews and captured major market share for a first year

    vehicle in the segment.

·One of 40 employees out of 600 hand selected into the Long Term Global Development Program,

    an initiative to develop future leaders in the Global Sourcing organization worldwide.

Oct 2001 - Nov 2004

Blackbelt Specialist

Led the resolution of chronic supplier components & capacity issues across all commodities

using “Blackbelt” lean manufacturing methodologies, including statistical techniques used to

resolve issues with objective data and documentation.

·Resolved Top 5 Quality & Warranty issues using statistical problem solving techniques saving

      over $4M.

·Under took additional assignments to manage advanced supplier quality activities for vehicle

      launches receiving Director’s Award for Supplier Quality contributions to the 2003 Pacifica launch

      in Canada.

Jan 1999 - Oct 2001

Supplier Quality & Process Specialist

Recruited to join a group of select commodity specialists tasked with the full lifecycle resolution

of various component & capacity issues at supplier facilities.

·Served as SME in advising assembly plants regarding launch build phase and the resolution

    of Nonconformance at the assembly plants and supplier facilities.

·Drove significant reductions in down-time, expediting costs, scrap / waste, and overtime.

·Volunteered for assignments to work with various product team launches of the PT Cruiser and

      Minivan.

Oct 1997 - Jan 1999

Quality Control Engineer: Steering Column Components

Assured quality compliance from over 300 global suppliers and the machining plant, evaluating daily

process performance, PPM statistics & tracking warranty issues.Conducted studies of new

machinery & processes prior to and including installation qualification.

·Resolved issues related to steering column components and reduced quality-related warranty

    costs 17%.

·Decreased manufacturing downtime by 26% through continuous process improvements that

      included the development of machinery and system performance analysis and process & gage

      capability studies.

·Analyzed warranty-tracking information for US and Canadian plants related to steering columns.

·Member of Documentation team for QS9000 audit that standardized Quality Documents.

·Performed machine capability studies at the suppliers’ facility on multi-million dollar manufacturing

    equipment, serving as final authorization for shipment and payment.

Sep 1996 - Oct 1997

Production Supervisor

Promoted to provide engineering expertise in manufacturing production and to supervise 100

hourly employees. Provided oversight for daily operations of the plant including Safety, Quality,

Delivery, Cost & Morale (SQDCM) and Good Manufacturing Practices (GMP), project planning /

execution, environmental and Manufacturing Quality Assurance System’s (MQAS/ISO) compliance.

Represented Toledo Plant for quality from Assembly Plants.

·Successfully supervised 100+ unionized employees in a High Volume, Lean Manufacturing

      environment.

·Achieved a customer complaint status of 0.0% for steering columns produced during the

     production shift.

Oct 1994 - Sep 1996

Quality Control Engineer: Torque Converter Components

Promoted to provide engineering expertise in manufacturing production and to supervise

100 hourly employees. Provided oversight for daily operations of the plant including

Safety, Quality, Delivery Cost & Morale (SQDCM) and Good Manufacturing Practices (GMP),

project planning / execution, environmental and Manufacturing Quality Assurance System’s (MQAS/ISO) compliance.Represented Toledo Plant for quality from Assembly Plants.

·Resolved issues related to torque converter components and reduced warranty cost by 12%.

·Managed plant-level basic and functional audits which improved overall process performance

      by 38%.

·Selected as a member of the New Product Launch Team.

Sep 1992 - Sep 1994

Project Manager & Engineer

Managed engineering projects for this major provider of natural gas for residential and

commercial customers.

·Selected by upper management for Rotational Program used to develop future corporate

      leaders through various short-term assignments to gain an overall prospective and knowledge

      of the company.

·Coordinated the quality, design, and installation of a $500,000 prototype CAD based

      image scanning system.

·Upgraded the document scanning process by implementing a CAD Media.

·Developed Request for Proposal, RFP, along with Purchasing and Legal departments

      for the purchase of document scanning equipment.

·Created and coordinated the supplier selection team, which included the revision

      and development of legal contracts, tracking project timing and managing budgets.

Education

Education
Aug 2003 - May 2005

Masters of Science

Sep 1986 - May 1993

Bachelor of Science

Skills

Skills

Continuous Improvement

Program Manager

Manufacturing

Total Quality Management

Technical Problem Solving

German Language

Interests

  • Golfing
  • Squash
  • Basketball
  • Football
  • Working Out
  • Politics
  • Jogging
  • Cycling
  • Travel

Summary

Quality Assurance (QA) Manager and Program Manager with demonstrated

ability to ensure the quality and integrity of products through the ongoing

evaluation of compliance of suppliers and plants with  corporate quality systems.

Highly adept at managing vendor / supplier relationships and adhering to best

practices in QA, QC, Production Operations, Engineering, Manufacturing

Operations, and New Product Introductions (NPI).Greenbelt and Blackbelt

well-versed in lean manufacturing,JIT inventory, Muda, continuous improvement

and supplier development. Consistent throughout career in providing root cause

analysis and resolution of routine and chronic supplier and process 

issues.MS in Engineering.

Certifications

Certifications

Blackbelt

Shainin LLC & Chrysler LLC

Greenbelt

Shainin LLC & Chrysler LLC