MEMBERSHIP
Member Profile: William Luka
OBJECTIVE
Seeking a Vice President / Director of Quality position in a manufacturing
environment. Looking for the right opportunity to utilize my quality
systems experience and industry knowledge with a company focused on customer
satisfaction and continual improvement.
MANAGEMENT PHILOSOPHY
I am a "hands on" manager focused on developing strong quality
systems. I continually monitor all major processes and capture and/or convey
best practices, inspire a commitment to quality and assist in the analysis
and implementation of corrective actions. I am data driven and drive
improvement from both internal and external quality data. I measure
quality performance through customer satisfaction and internal quality
metrics. I monitor supplier performance and ensure that all requirements
are known and properly implemented. I am a strong advocate of
advanced quality planning and champion "new product launch"
to ensure process capability and consistent product performance throughout
its life cycle.
EMPLOYMENT HISTORY
Quality Systems Consulting - Senior Consultant - April 2002 to Present
Currently self employed and working as a Senior Consultant since early
May for a major Tier 1 supplier to GM & Ford. I am implementing
an ISO/QS-9000 quality system in a start-up plant involved in a new
product launch. Prior to my current assignment, I had several
auditing assignments for other Tier 1 suppliers seeking QS-9000 registration
in a "green field" operation or assistance with their present
quality system.
Key Plastics, LLC - Vice President - Corporate Quality - Oct. 1993
to Dec. 2001
Corporate Quality responsibility for multiple plants in North America
and Europe with $650 million in sales specializing in plastic processing,
assembly, decorating and painting for the automotive industry.
Responsibilities included:
(1) champion of ISO/QS-9000 and ISO-14001 implementation and maintenance,
(2) managed ISO/QS-9000 internal audits & corrective action plans
for audit discrepancies and served as the Registrar liaison for the
registration process, (3) managed the collection and analysis of QOS
quality data for problem resolution, continuous improvement and measurement
of customer satisfaction, (4) monitored supplier quality and delivery
performance, conducted quality system audits and managed
supplier APQP activities in respect to PPAP and process/product capability
requirements and (5) managed the internal APQP process including sample
submission, "run at rate" review and launch readiness.
Major accomplishments:
-Instrumental in changing Key Plastics' Ford supplier classification
from "short term eliminate" to "best in class" in
14 months improving ppm from 8615 to 31.
-Wrote Key Plastics' "Supplier Handbook" emphasizing quality
system development and APQP requirements leading to a 68% improvement
in supplier launch performance.
-Reduced ppm an average of 50% within the first 6 months for each acquisition,
(calendar years 1997 and 1998).
-Achieved QS-9000 Registration (within 8 months of ownership) for the
North American acquisitions (8 locations in 21 months) October 1997
through June 1999
-Achieved 50% ppm reduction corporate wide in 1998 & 1999 and 38%
in 2000.
Ford Motor Company - ELD - Division Supplier Quality Engineer - Jan.
1990 to Oct. 1993
STA responsibility for electrical connectors, plastic components &
assemblies and chemical commodities. Actively involved in advanced
quality planning, quality systems auditing and problem resolution.
Trained and developed new engineers joining the department in basic
auditing and problem solving techniques. The position provided
a unique opportunity to audit a vast number of Tier 1 companies and
compile "best practices" as well as analyze
various operations and management styles.
Major accomplishments:
- Improved supplier performance by 65% (measured in QR's and ppm)
- Instrumental in the development and launch of the Ford Quality Operating
System, (QOS)
Aeroquip Corporation -Director - Quality & Reliability - March
1986 to December 1989
Corporate Quality responsibility for twelve plants with $250 million
in sales specializing in injection molding, SMC, assembly, decorating
and painting for the automotive industry.
Responsibilities included:
(1) implementation and maintenance of quality systems, (2) conducting
internal audits and developing corrective action plans (3) managed the
collection and analysis of quality data for problem resolution and continuous
improvement, (4) managed the supply base through quality and delivery
metrics, on-site quality system and process/product audits as well as
a review of PPAP submissions and launch performance, (5) management
of the internal APQP process including sample submission, layout and testing
and (6) customer liaison on all quality issues and served as the primary
customer SQA contact.
Major accomplishments:
- Regained Ford Q1 (5 locations) within 6 months of joining Aeroquip
- Developed Corporate Quality Training function focusing on problem
solving resulting in a 95% reduction in repeat issues within the first
year.
- Improved supplier performance by 41% through a "supplier development
program" focused on APQP involvement and on-site system process/product
monitoring.
- Wrote and issued Aeroquip "Supplier Handbook".
- Instrumental in obtaining a 62% reduction in external customer ppm
within the first year for 7 LOF plants that were merged into the existing
corporate system.
- Reduced PPAP submission time and cost by 57% through the development
of a corporate quality layout and product testing laboratory function
Jim Robbins Company - Corporate Quality Manager - August 1985 to
March 1986
Corporate quality responsibility for a two plant operation having $60
million in sales specializing in plastic processing, assembly, decorating
and painting for the automotive industry.
Responsibilities included:
Implementation and maintenance of quality systems, problem solving &
implementation of corrective actions, customer liaison on all quality
issues and primary customer SQA contact.
Major accomplishments:
- Established comprehensive purchased component inspection and out-sourcing
function
- Obtained Q1 for two locations
A.M.P. Industries - Quality Manager - August 1979 to July 1985
Quality responsibility for a one plant operation with $30 million in
sales specializing in plastic processing and assembly for the automotive
and non-automotive industry.
Responsibilities included:
Implementation and maintenance of quality systems, problem resolution,
supervision of inspection personnel, sample submission, customer liaison,
receiving inspection and supervision of contracted painting operation.
Major accomplishments:
- Established nylon testing laboratory to Ford requirements
- Established color analysis and part layout laboratory
- Developed color qualification system for sub-contracted painted parts
Merit Plastics - Quality Manager - March 1971 to July 1979
Quality responsibility for a one plant operation with $15 million in
sales specializing in insert molding, cable and harness fabrication
and assembly for the automotive industry
Responsibilities included:
Supervision of inspection personnel, maintenance of quality systems,
problem resolution, supplier quality, customer liaison, maintenance
of Ford Q-101 and customer SQA contact.
Major accomplishments:
- Developed supplier quality surveillance & evaluation program
- Implemented SPC on all fabrication & core cutting lines
EDUCATION
Master of Business Administration - Wayne State University 1976
Master of Arts - Central Michigan University 1969
Bachelor of Science - Central Michigan University 1967
PROFESSIONAL CERTIFICATIONS
ASQ Certified Quality Manager # 03618 (October 1998)
RAB Certified Quality Management Systems Lead Auditor #Q03050 (August 1994)
ASQ Certified Quality Auditor # 1527& (June 1990)
ASQ Certified Quality Engineer # 16834 (December 1987)
PUBLICATIONS / PRESENTATIONS
Co-authored Ford Motor Company Quality Operating System (QOS) Manual
Committee Member - Ford Motor Company Quality Operating System Assessment
Guidelines
Co-presenter "QOS Methodology" - University
of Michigan "Management Briefing Seminar"
Presenter - "QS-9000 Implementation Strategy" MRI Conference
SEMINARS AND CERTIFIED COURSES
ISO/TS16949 Transition Seminar - STAT-A-MATRIX 2002
Global 8-D - Ford Certified Trainer 2001
ISO-9001:2000 Transition Seminar - STAT-A-MATRIX 2001
ISO-14001 Implementation Seminar - STAT-A-MATRIX 2000
ISO-14001 Seminar IQuES 1999
ISO-9000 Lead Auditor Training - Perry Johnson Inc. 1996
QS-9000 & QSA Training - AIAG 1994
ISO-9000 Lead Auditor Training - ARCH Associates 1993
GD&T; - Ford Motor Company 1992
Ford QOS - Eastern Michigan University 1992
Dale Carnegie Course 1982
PROFESSIONAL ORGANIZATIONS
American Society for Quality (ASQ) (Member since 1983 - and "Fellow"
since 1997)
Executive Advisory Board - Perry Johnson Registrars 1997 - present
Chair and elected offices (ASQ Human Development & Leadership
Division) 1995 - 2002
Vice Chair - Professional Development (Greater Detroit Section - ASQ) 1990 - 1992
INSTRUCTOR
Ford Motor Company "Quality Operating System" (QOS) - methodology
& implementation classes August 2002
