Lean Manufacturing, SPC and FMEA Expert Consultant Resume
Resume of KMZ Consultant

  • Aerospace
  • Automotive
  • Consumer Software
  • Environmental
  • Manufacturing
  • Medical Devices
  • Research Facilities
  • Robotics
  • Telecommunications

This expert has an M.S. in Engineering from Syracuse University.

This expert received a B.A. in Psychology and Philosophy from Columbia University.

Lean Manufacturing, SPC and FMEA Expert Consultant Resume

This expert specializes in quality automotive standards, AIAG core tools, APQP, PPAP, MSA, SPC, and FMEA. Further expertise includes magnet wire continuity, problem solving techniques, classical DOE, and Taguchi and Shannon. Other relevant areas of expertise are lean manufacturing, process mapping, 5S, SMED, TPM, standardized work, Kan Ban, and mistake-proofing.

This associate offers expertise specific to Operator Driven Quality programs, the Toyota Production System, ISO, and TS quality management systems. Other expertise this consultant encompasses includes TS auditing, Sarbanes-Oxley Act, controls verification, and ISO information technology standards. Related fields of specialty for this expert are security software standards, ISO 17799, process auditing, and registration. Furthermore, this expert specializes in upgrade audits, auditor training, and FMEA.

Expertise includes ISO, TS 16949, ISO 9001 QMS, QS-9000 automotive, ISO 17025 laboratories, ISO 13485 medical devices, with ISO 14971 risk analysis and CFR 21-820, ISO 14001 environmental, AS 9100 aerospace, TL 9000 telecommunication, ISO 90003 and ISO 12207, 9126, 14589, and 17799 Software standards.

Additional areas in which this expert has knowledge include public park playground equipment, paint systems design and installation, electrostatic powder coating systems, and powder-coat magnet wire. This expert has other experience including small motor manufacturing, SPC, development of corporate QS-9000 systems and registration of all locations.

This expert has provided ISO and Quality Management Systems Consulting in areas including OE alternators and starter motors and re-manufacture of multiple automotive and locomotive components, intangible intellectual product, large steel castings, and registration audits for manufacture of rare earth magnets system. Other areas of expertise in this consultant's background include manufacture of o-rings and seals, processing of hazardous and restricted waste, manufacture of diesel engines, and Quality System Training for consumer products mixers. Furthermore, this expert specializes with magnet wire manufacture, quality and productivity improvement for container manufacture, manufacture of specialty machines, and calibration and electronic repairs. Other related expertise of this consultant entails custom plating, consumer cleaning products manufacture, manufacture and re-manufacture of drawing dies.

Additional ISO and Quality Management Systems Consulting includes manufacture of precision wire, manufacture of large manufacturing equipment, plating wide strip, and blending of custom silicone materials. Other related specialties include corrugated box manufacture, steel fabrication including painting, custom machinery and gaging, and plastic dielectric parts and materials. Other specialization entails rapid-response pattern-making and casting, manufacture of bolts and nuts, tool manufacturer specializing in broaches, and software design of off-the-shelf telephony programs to replace PBX.

This expert has additional experience and specialization including Shainin-based design of experiments for manufacture of welded aluminum automotive components, development of ISO 14001 registration programs, introduction of SPC based process control for manufacture of replacement windows, and manufacture of electro-mechanical appliance controls. Specific expertise of this consultant includes APQP, PPAP, FMEA, MSA, and SPC training. Other specific emphasis includes manufacture of various automotive components, manufacture of various automotive components, process improvement, and logistics organization serving the drug industry.

Consultant, Kevin Kennedy Associates Inc.

Providing quality and process engineering, quality management, lean consulting, SPC, FMEA and problem solving consulting, failure analysis, forensic engineering and related expertise to a wide variety of clients.


ISO and Quality Management Systems Consultant

Taught ISO and QS, including the 5 AIAG core tools, and problem solving, including classical DOE, Taguchi and Shannon techniques. Taught FMEA to the Indiana Manufacturers Association and the Fort Wayne, Indianapolis, and Bloomington ASQ sections. Assisted organizations to register to ISO and the derivative standards, including ISO/TS 16949. Eventually partnered with the Indiana Business Modernization and Technology Corp. (an arm of the Indiana Department of Commerce) to present public classes in several Indiana locations (Fort Wayne, Peru, Muncie, Indianapolis). Presented advanced FMEA classes at the Indiana Manufacturers Association annual conference, and in Fort Wayne for the local ASQ annual conference. Also assisted approximately 50 QS-9000 registrations during this period. Partial client list includes Delco Remy America, Eaton Controls and Suspension, Delphi, DANA, Phelps Dodge, and Essex. Created a transition training class which was accredited by the RAB for auditor transition, and assisted Mannesman in Auburn to register to VDA 6.1. Assisted Magnequench in Juarez, Mexico, to register, which was the first ISO/TS audit in the Americas. Acted as a consultant for the IAOB as witnessing auditor. Guided many other companies including Innovative Casting, Engineered Cooling Systems, Industrial Dielectrics, Global Plastics to TS registration. Taught TS to many organizations including Essex and Kimball. Developed the in-house TS training materials for International Truck and Engine group. Acted as a Lean consultant, assisting organizations with SPC and design of experiments. Developed 4 web-enabled shop-floor data collection and process control systems for Essex, Phelps Dodge, and Magnequench. Authored programs in HTML PHP, and the various Basic programs (Alan Bradley, Modicon, and OPTO 22 shop floor controllers, and Hitachi Robots). Taught T-mapping and Plain Writing. Trained and assisted clients with ISO/TS 16949, ISO 9001 QMS, QS-9000 Automotive, ISO 17025 Laboratories, ISO 13485 Medical Devices (with ISO 14971 Risk analysis and CFR 21-820), ISO 14001 Environmental, AS 9100 Aerospace, TL 9000 Telecommunication, ISO 90003 and ISO 12207, 9126, 14589, and 17799 Software standards.


Quality Manager, Essex Group, Inc., Fort Wayne IN

Directly responsible for 11 plants (led them in understanding the 5 AIAG manuals and how to apply the Core Tools), and “dotted line” responsibility for 27, leading them to ISO 9001 registrations and then upgraded to QS-9000. Guided all the plants to ISO or QS registration, and the laboratory to ISO guide 25 with A2LA. Led the first Indiana QS registration (witnessed by the RvA) one of the first 50 in the world. Taught QS-9000 and the 5 AIAG core tools to all the plants and selected suppliers and customers. Developed a Problem Solving methodology using a broad range of statistical techniques from Shannon to Taguchi, and including the classical ANOVA.


Quality and Process Engineering Manager, Essex Magnet Wire Plant, Franklin, TN

Led the plant team to the first Targets for Excellence certification, which passed on the initial audit and was Q1. As a tier 1 to Ford and GM, submitted PPAPs, including all the required FMEA, GRR, Cpk, etc. Presented papers to the SMMC (Small Motor Manufacturing Conference) on the use of SPC and Cpk based on the Poisson distribution for electrical continuity. The plant provided alternator and starter motor wire to their automotive customers. They drove returns from 40,000 PPM to 250 PPM.


Chief Engineer, Interrad

Was responsible for designing and installing the paint systems at the GM Wentzville and Orion assembly plants. Supervised the installation of the world’s largest powder coating system in the GM Shreveport LA assembly plant. Developed a robotic fascia painting system for the Ford plant in St. Louis. Assisted in the design and development a plant for Electrostatic Technology in New Haven, CT, to electro-statically powder-coat magnet wire for use in transformers. The plant was subsequently leased to Phelps Dodge, and the technology is still in use at the ABB plant in Rome, Georgia.


Manager, Wooden Environments Inc.

Was responsible for design, manufacture, and installation of public park and playground equipment from Boston to Washington. Managed a 25,000 sq. ft. plant with 60 employees.

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Peter Habicht, Lead Consultant
Peter specializes in welding and metallurgical engineer with 40 years industry experience in commercial nuclear power plant construction.


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