CHARLES JOHN STICKNEY

MS BS ASQ CQE CQA ISO TS

3650 Windwood Court Rochester MI. 48306
H: 248.601.1422 C: 248.933.2126
E: cs911204@westpost.net
SUMMARY OF SKILLS AND QUALIFICATIONS

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Quality Manager a" Senior Quality Engineer highly organized and
energized self-starting professional who is a success oriented team
player with strong analytical skills. Possess excellent written,
oral, and interpersonal communication skills. Ability to thrive in a
fast paced challenging environment with integrity and
professionalism. Focus on strong client service with excellent follow
up skills and an aptitude to prioritize and multi-task.
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Responsible for Advanced and Current Product Development Engineering
and Management.
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Expertise in Product Supply Chain Engineering with developing,
implementing and auditing a range of products, materials and
manufacturing processes required for product development working with
both internal and external processes for domestic and international
suppliers.
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Proficient at APQP and product development management leading PPAP
for advanced and current product development through PPAP with
manufacturing equipment and processes required in production.
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Conduct on-site audits and qualify suppliers based on observations
and actual production product dimensional data and conduct capability
studies on the development of components and products.
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Develop/implement Six Sigma processes and lead improvement
activities to create and maintain lean manufacturing strategies while
tracking critical program timing to meet the customer requirements.
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Audit Six Sigma's methods and the use of measurement and improvement
tools, and in communications and relationship skills.
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Lead Six Sigma DMAICT teams and team leaders responsible for
implementing process elements.
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D - Define opportunity, M - Measure performance, A - Analyze
opportunity
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I - Improve performance, C - Control performance, T - Transfer best
practice
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ENOVIA PLM product lifecycle management utilized to support the
product development processes from concept CATIA design to
manufacturing.
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Quality Function Deployment (QFD) is a method of product development
where the product or process is directed from the Voice of the
Customer (VOC) through development of requirements, specifications
design feature development, process selection and process control.
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Design Verification Plan and Report (DVP inspection processes and
documentation; vendor outsourcing to lower tier vendors
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Conduct on-site vendor certification for current and new suppliers
for product development. Liaison with Design engineers to achieve
Design for Manufacturing and assembly.
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Coordinate vendor transitions and start-up operations with
development into fully functional suppliers.
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International experience working with Chinese, British, German,
Italian and Canadian companies.
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Lead Failure Modes Effects and Analysis (FMEA) and Failure Modes,
Effects and Critical Analysis (FMECA) to achieve high quality
designs, processes, and services that meet or exceed industry
standards.

PROFESSIONAL EMPLOYMENT EXPERIENCE

BAE SYSTEMS/FORCE PROTECTION INDUSTRIES INC. CHAMBERSBURG

PA/CHARLESTON SC. 2007 a" 2010
SENIOR PRODUCT DEVELOPMENT AND MANUFACTURING SYSTEMS CAPABILITY
PROCESS ENGINEER AND CURRENTLY CONSULTING
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Program Management responsible for product development and planning
of capital equipment required for producing MRAP vehicles for the
Military. Leading both People and Projects, developing product and
processes that drive improvements initiatives for Six Sigma lean
manufacturing. Strategies and the acquisition of new
equipment/processes, workplace layouts, labor and material flow with
business process modeling to meet company strategic goals.
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Manager of both Internal and External Product Development leading
the DFMEA Team in a suitable design and system components to ensure
the safety and reliability estimation and analysis of the system.
Utilized QFD within the Product Development Team, for ensuring that
requirements are captured, disseminated, monitored & controlled to
ensure compliance with customer, legislative, drawings,
specifications including training those who will use the new business
process models.

ACCOMPLISHMENTS:
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Created a Six Sigma lean process for vehicle development which took
the company from producing 2 mine resistance ambush protected vehicles
(MRAP) per month to 54 vehicles last month netting $54 Million in
sales which completed the two year Government contract.
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Develop, investigate and solve manufacturing process to improve
cost, quality, delivery and safety of manufacturing processes by
value stream mapping and improving process flow by (75%) seventy five
percent.
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Improved first time through process capability from a 50% failure
rate to 1- 2% failure rate found at final inspection.

RAPID GLOBAL BUSINESS SOLUTIONS INC. TROY, MI 2004-2007

SENIOR QUALITY AND SUPPLY CHAIN ENGINEER ON ASSIGNMENT TO:

JOHNSON CONTROLS SEATING TOYOTA BUSINESS UNIT, PLYMOUTH, MICHIGAN

ONE YEAR CONTRACT
SENIOR QUALITY ENGINEER SUPPLY CHAIN AND CUSTOMER QUALITY 2006

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Managed Toyota Business Unit Product Development Team to ensure the
quality of supplier pre-production for plastic, foam and stamped metal
components through use of APQP tools. Responsible for
equipment/processes to accommodate and build part design validation
and gauging serving as the key manufacturing representative between
supplier and engineering on Toyota programs and in meeting part
requirements for producing both pre-production and production seat
build activities. Led the JCI Toyota Product Development Teams and
external Supplier Development Teams with new product development.
Responsible for ISO and TS conformance requirements.

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Provided technical guidance for quality systems, customer support,
supplier assessment, and problem solving facilitation. While at JCI
assisted Quality and Production departments in daily activities.
Utilizing practical applications of quality tools and worked
operational management roles as a mentor and coach with plant
production management and employees. Serve as a direct quality and
production responsible manager of a corporate technical team as well
as a successful consultant responsible for serving both the advanced
and industrial manufacturing sectors in the product development
processes. Conducting in house on-site Product development and
capacity analysis review of run at rate line speed demonstrations in
meeting daily and annual production volumes. Conducting risk
evaluations and completing internal audits.

ACCOMPLISHMENTS:
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Full Customer a" Toyota PPAP Level 3 PSW approval for my APQP work
with the entire Toyota Product Development Teams both internal
customer and external supplier development.
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JCI was awarded the Toyota Business Account with an estimated
volume of three hundred thousand vehicles.
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Received a letter of recommendation for my contributions work
performance and team ethics from the Director of JCI.

FAURECIA AUTOMOTIVE SEATING, AUBURN HILLS, MICHIGAN ONE YEAR

CONTRACT EMPLOYMENT
SENIOR QUALITY ENGINEER SUPPLY CHAIN MANAGEMENT 2005

* Manager of Supply Chain Development Analyzing Information,

Reporting Results, Technical Understanding, Promoting Process
Improvement, Developing Standards, Managing Processes, Manufacturing
Methods and Procedures, Supports Innovation, CAD, Quality Engineering
and Operations. Responsible for serving as the key quality management
representative between the suppliers on part requirements to meet
daily production build activities. Lead the Product Development Teams
and external Supplier Development Teams with new product development.
Addressing supplier capabilities product validation and addressing
non-conformance to design requirements
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Lead supported and provided technical guidance for quality systems,
customer support, supplier assessment, and problem solving
facilitation. Assist the Purchasing, Quality, and Production Control
departments in day to day activities. Provided practical applications
of quality tools and worked operational management roles as a mentor
and coach with plant production management and employees. Serve as a
direct quality and production responsible manager of a corporate
technical team as well as a successful consultant responsible for
leading both the automotive and industrial manufacturing sectors in
the product development processes and production manufacturing.
Managerial and system related responsibilities have included both
quality and engineering management in product launch and production
activities including supplier development.

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Durability & Reliability testing carried out in both design and
non-design responsible production and supply chain management.
Involvement includes the studying of the Scrap and Cost Reduction
Programs including leading and the facilitation of new product launch
conducting on-site capacity analysis review of run at rate line speed
demonstrations in meeting daily and annual production volumes.
Conducting Supplier risk evaluation for new source selection and
completing both internal and external audits. Responsible for ISO and
TS conformance requirements.

ACCOMPLISHMENTS:
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Full Customer a" GM PPAP Level 3 PSW approval from my APQP work on
the Pontiac G-6 with the entire GM Product Development Teams internal
customer and external supplier development.
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Faurecia was awarded the GM Business Account for the Pontiac G-6
with an estimated volume of two hundred and eighty thousand vehicles.
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Received a letter of recommendation for my contributions work
performance and team ethics from the Quality Manager.

AMERICAN SPECIALTY CARS, OAK PARK, MI, CONTRACT EMPLOYMENT

SENIOR QUALITY RELIABILITY ENGINEER SUPPLY CHAIN DEVELOPMENT AND
CUSTOMER QUALITY 2004

* Manager of product development team to ensure quality of

production components PPAP through use of APQP tools.
Responsibilities: Sheet metal BIW, castings and forgings on power
train and chassis. Serving as the key quality management
representative between engineering and suppliers on part requirements
for production build activities. This entails assessing supplier
capabilities product validation and addressing non-conformances to
design requirements. Utilized Reliability and Product Life-cycle
Management PLM software as an integrated tool for product life-cycle
analysis. Provide guidance to other Advanced Supplier Quality
Engineers on PLM usage. Develop and implement best business practices
for product development and the approval processes.

ASC DESIGNED, DEVELOPED AND MANUFACTURED THE GM CHEVY SSR SIGNATURE

SERIES TRUCKS:

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Product development Quality and Reliability planning
(Interior-Exterior). Support vehicle platform reliability and
warranty analysis. Worked on RFQ in case ofProgram taking into
consideration surrogate warranty. Lead warranty agreement meeting by
forecasting warranty from trend analysis. Involvement with design
engineer for future product Reliability Predictions. Characterizing
statistical life fatigue parameters with reliability simulation
software.
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Lead the Customer GM team to ensure quality and reliability of
production components through use of APQP tools. Responsibilities:
Sheet metal BIW, castings and forgings, power train and chassis.
Reliability predictions were used to evaluate and improve product and
system reliability. ASC had to meet or exceed the Reliability and
Warrant requirements per GM terms and conditions. I was responsible
for the Quality planning of both assembly and component level.
Program Management to include tracking of events and team management
toward quality goals at the supplier level and customer level. Drive
continuous improvements activities while developing work plans for
the Quality Department. Coordinate APQP meetings and activities for
the Quality Team. Conduct Supplier On-site Process Approval to assure
Quality and On-Time delivery of components and sub-assemblies.
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Develop processes and plan capital equipment to support Prototype,
Pre-Production, and Production, requirements for PPAP parts to obtain
customer approval of the Part Submission Warrants. Develop solutions
to quality related issues while watching costs and minimizing risks.
Coordinate with other Departments and audit Departments and provide
quality improvement leadership to ensure effective and efficient.
Define development implement and train new processes for team
building, quality, safety, housekeeping, costs and timing for
implementation. Track organizational goals and ensure team members
are in compliance with company policies and procedures. Work with
Engineering to determine significant key characteristics and track
performance both internal and external.

ACCOMPLISHMENTS:
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Full Customer a" GM PPAP Level 3 PSW approval from my APQP work on
the GM Chevy SSR Signature Series Trucks with the entire GM Product
Development Teams internal customer and external supplier
development.
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ASC was awarded the GM Business Account for Design Development and
Production of the GM Chevy SSR Signature Series Trucks with an
estimated volume of fifty thousand vehicles at $50K each.
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GM Lead SQE and Program Manger requested ASC to provide my services
and presents on all the GM Chevy SSR Signature Series Truck Business.
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Received a letter of recommendation from my contributions work
performance and team ethics from the Quality Supervisor.

DAIMLERCHRYSLER AUBURN HILLS, MICHIGAN CONTRACT EMPLOYEE 1997-2003

CORPORATE QUALITY MANAGER
* Lead and Champion for QS ISO and TS registration activities
for DCX Corporate Quality Vehicle Platform Support including Supply
Chain. Responsible for the development of the required documentation
with procedures, work instructions, training, implementation and
auditing of all three Standards QS, ISO and TS. Developed and
completed internal auditor training courses (QS9000, ISO 9001, and
TS16949). MRB (Material review board) run (scrap, rework, return to
supplier transactions). Development Internal audits and documentation
as per requirement of QS, ISO, TS. Conduct Surveillance audits through
both internal and external DCX Corporate Sites and Supply Chain
validating Quality System compliance. Auditor and team leader in
developing, implementation, training and auditing to the required
standards.

SENIOR MANUFACTURING & RELIABILITY ENGINEERING SPECIALIST

* Manager of a Product Development Team leading workshops
regarding internal/external awareness in Product Development Progress
and Process Sign-Off (PSO) analysis and usage of Powerway.com with PLM
software as an integrated suite of Product Life-cycle Management.
ENOVIA PLM utilized to support the product development processes from
concept CATIA design to manufacturing. Co-ordinate, Facilitate, and
Lead Product & Process Teams for Advanced Product Quality and
Reliability Planning. Responsibilities include leading Product
Development Teams on Concurrent Engineering, New Product Development
and systems reliability predictions Product Change Management
utilizing CATIA 3D CAD for product design changes and Powerway.com
for tracking Supplier development. Provide DCX Production Plants the
support and technical guidance for improving quality systems,
customer support, supplier assessment, and problem solving
facilitation.
PROCUREMENT & SUPPLY QUALITY PROCESS IMPROVEMENT SPECIALIST,
SUPPLIER DEVELOPMENT ADVANCED PROJECTS, RESPONSIBILITIES,
CO-ORDINATION OF ADVANCED PRODUCT AND PROCESS QUALITY PLANNING (APQP)
ACTIVITIES.
Process Consultant and Facilitator leading the implementation of 6
sigma culture in union environment for the following Platforms
minivan, truck, large and small car. Lead Six Sigma DMAIC approach
for effective reduction in overall costs and warranty long term.
Managed internal Product Development Teams and Supplier Development
Teams with the APQP PSO PPAP. Activities include the definition,
implementation, and improvement of internal and external supplier
quality-related practices and procedures in supporting the
organization with services and solutions using Quality Tools in
meeting company goals and objectives.

ACCOMPLISHMENTS:
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Implementation of 6 sigma reduction in scrap and rework by (30%)
thirty percent.
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Kepner Tregoe's approach, implementation of quality system in union
environment.
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Design of Experiment (DOE) and capability study for AC/HVAC proved
to be successful the Sebring AC/HVAC Dealer warranty cost dropped
dramatically thirty percent (30%) over the next ninety (90) days.
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Sebring production of the Heater Core for the AC/HVAC System (60%)
fall-out of Heater Cores during production. SPC monitoring and
controlling their in-house manufacturing processes the fall-out or
failure rate was reduced by sixty percent (60%).
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Dodge Durango platform manufacturing production plant seventy five
percent (75%) fall-out for drips and sages on the rocker panels paint
line. Redesigned the Rocker Panel to correct these failures. Results
went from a seventy five percent (75%) failure fall-out rate to zero
percent (0%) failure fall-out rate.
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 Design the Chrysler 300M responsible for facilitating the DFMEA for
this new concept vehicle for the Daimler European Market. Discover
failure modes European garages were smaller than the average USA
garages. I approached the PDT with my finding and the decision was to
reduce the vehicle length. The Design teams redesigned the 300M and
shorten the vehicle by reducing the trunk size and deck lid. The
redesigned trunk and deck lid style appealed to both the European and
the USA Markets. The style won JD Power Awards for Car of the year.
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Receiving certification to QS9000:1994, ISO 9001:2001 and
ISO/TS16949:2002 Standard from United Laboratories.
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Promoted three times in five years and part of team for Malcolm
Baldridge Award.

PLASTIC SPECIALTIES INCORPORATED, TROY, MICHIGAN CONTRACT TO DIRECT

EMPLOYEE 1985-1996
MANAGER QUALITY ASSURANCE
* Supervised a three-shift 37 technician's high speed
injection molding and assembly production operation.
* Responsibilities: APQP and PPAP Develop Procedures and
Standards for the quality control of both automotive and
non-automotive components. Lead Product Development Teams and
external Supplier Development Teams with the product development and
execute audits of company policies and procedures.
* Supervised incoming, in process and final inspection to
maintain the quality and control of components, sub-assemblies and
final assemblies.
* Included Prototype, Pre-Production, and Production
components and assemblies.
* Coordinate and lead the following activities: FMEA (Design &
Process), GD&T, MSA, Control Plans, Error/Mistake Proofing,
Engineering development and testing, Analyzed DVP&R test results and
made appropriate changes.
* Lead and Responsible for Certification to the QS-9000
consists of the following basic steps: 1) Review of the QS9000
document standard and its support literature and software; 2)
Organizational preparation and assembly of a team that will oversee
the certification; 3) Development of a Quality Manual that meets the
QS-9000 requirements; 4) Development of support documents for your
Quality Manual; 5) Implementation of the quality management systems
defined in your Quality Manual; 6) Pre-assessment of your quality
systems (optional); 7) Certification to the QS-9000; 8) Continual
assessment of your quality systems against QS-9000 requirements to
maintain your registration.

ACCOMPLISHMENTS:
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Customer support relationship increased business ten percent (10%)
per year and upward to fifty percent (50%) by the fifth (5) year
which doubled the business at PSI.
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Develop train and implement procedures for structured, systematic
approaches to manage on-site Manufacturing and Supplier Quality. The
new Quality System began to monitor and/or control the quality level
of production components being supplied by preferred suppliers.
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The new Quality System proved itself to be a success within ninety
(90) days with a twenty (20%) increase in productivity and a direct
reduction in manufacturing downtime.
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Quality System developing the Plants and Supplier Development with
Quality Policies, Procedures, Product Requirements, Roles and
Responsibilities.

EDUCATION
Masters of Science - Engineering Industrial Manufacturing Quality,
1997, Eastern Michigan University, Ypsilanti, MI.

Bachelors of Science - Math and Chemistry, 1995, Oakland

University, Rochester, MI.