Marc G.

Gast
2155 Negaunee Dr. SE
Grand Rapids, MI 49506
Email address: mgd09622@westpost.net
(616) 304-5466
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PROFESSIONAL EMPLOYMENT
Functional Experience:
a Over 20 years manufacturing experience (automotive, aerospace, commercial, mil
itary, medical), including 12 years maquiladora experience - plant floor involve
ment, supplier / sourcing development and on-site support at O.E.M. manufacturin
g sites.
a Tier 1, II, III levels and O.E.M. interface - in plant floor involvement, and
on-site support at O.E.M. manufacturing sites.
a Quality systems development / deployment including writing of quality manuals,
inspection / work instructions, including training personnel on new procedures/
process.
a New product launch program - directly involved with product design, APQP devel
opment of products / processes and direct interface with customer.
a FMEA development - including involvement in DFMEA / PFMEA / Process Flow / Con
trol Plans, including development / deployment of training programs.
a Supplier development - including internal development of supplier metrics / su
pplier quality manuals/ tracking supplier performance and performing audits.
a Problem solving - including hands on corrective/preventive actions utilizing S
ix Sigma / Kepner-Tregoe, 5-Why / T.O.P.S and involvement in Kiazen / Lean impro
vement processes.
a Over 20 years auditing experience - 1st / 2nd / 3rd Party Currently certified
to TS1694 9 / ISO9001 / AS9100 / ISO20252 / Ford Q1 / VDA
a Development / deployment / analysis of Statistical Process Controls/including
analysis of internal/external PPMs, along with Green Belt Certification (utilizi
ng MiniTab).
Achievements:
a Developed quality systems that achieved a 0-100-30 Launch Rating - Mercedes M-
Class vehicle.
a Participated in Black Belt project reducing external PPMs from 55, 000 to 0.
a Team member awarded the Chrysler Silver Pentastar (cost savings of $500,000.00
at O.E.M. assembly plant).
a Identified supplier product manufacturing process deficiencies and implemented
actions that eliminated PPMs (100,000 - 0).
a Identified a design error (stack-up) that resulted in elimination of defects a
nd improved assembly processes.
Supplier Quality Engineer
Stryker Instruments - Kalamazoo, MI
07/2010 - Present
Contract Position
a Responsible for review and approval process of supplier corrective actions.
a Involved in improved closure timing project for corrective actions.
a Support of manufacturing line for supplied medical component issues.
a Monitoring of supplier metrics.
a Support processes for commodity teams.
Certified Lead Auditor / Consultant
Contract Auditor, - Grand Rapids, Michigan 12/2009 - 09/2010
Certified Lead Auditor 3rd Party Auditor - AS9100 AA, ISO9001:2000/2008, ISO2025
2, TS16949:2002/2009
Certified Lead Auditor - Internal Audits / 2nd Party Audits
a Performed 3rd Party surveillance and reassessment audits as Lead Auditor and A
udit Team Member.
a Industries audited included marketing research firms, chemical plants, aerospa
ce product manufacturing, extruded metal forming, insert molding, laser metal f
orming, liquid / powder paint formulating, metal stamping, plastic injection mol
ding, precision metal forming / finishing, rubber injection molding, tire manuf
acturing, tool / die manufacturing, metal welding operations, hot/cold metal for
ging, machining, tool design/manufacture, railroads, assembly sequencing operati
ons, electronic module assembly, credit counseling, fiberglass production, wire
termination / harness assembly wire/ spring forming.
a Audits include review of Key Metrics/ Quality Systems Management, review of al
l processes (APQP, manufacturing - on floor, lab/calibration/corrective and prev
entive actions).
a Developed/deployed audit plans.
a Managed client accounts for scheduling audits, preparing reports and review of
corrective actions.
Client Manager/Certified Lead Auditor
BSI Management Systems - Reston, Virginia 07/2006 - 12/2009
AS9100 AA, ISO9001:2000/2008, ISO20252, TS16949:2002/2009 Certified 3rd Party Au
ditor
a Performed audits as Lead Auditor and Audit Team Member.
a Industries audited included extruded metal forming, insert molding, laser meta
l forming.
liquid / powder paint formulating, metal stamping, plastic injection molding, pr
ecision metal forming / finishing, rubber injection molding, tire manufacturing
, tool / die manufacturing, metal welding operations, hot/cold metal forging, ma
chining, tool design/manufacture, railroads, assembly sequencing operations, ele
ctronic module assembly, credit counseling, fiberglass production, wire terminat
ion / harness assembly, wire spring forming, marketing firms.
a Developed audit plans.
a Managed client accounts for scheduling audits, preparing reports and review of
corrective actions.
Quality Assessor II 01/2006 - 06/2006
Intertek Systems Certification - Grand Rapids, Michigan
a Performed 3rd Party Audits (Lead Auditor/Audit Team Member).
a Industries audited included tire manufacturing, extruded metal forming, fiberg
lass insulation
formulation, hot runner/sensor / thermocouple assembly, insert molding, laser me
tal forming,
liquid / powder paint formulating, metal stamping, plastic injection molding, po
lycarbonate
component forming, precision metal forming / finishing, rubber injection molding
, solvent
manufacturing, tire manufacturing, tool / die manufacturing, metal welding opera
tions,
wire termination / harness assembly and wire spring forming.
a Developed audit plans.
a Achieved ISO9001:2000 Auditor Certification through Intertek Systems Certifica
tion.
Quality Engineer / Supplier Quality Engineer 2002 - 2006
Johnson Controls, Inc. - Holland, Michigan
a Lead auditor / performed internal Q.M.S. / Product / Process Audits per ISO /
TS16949:2002 / JCI B.O.S. Standards.
a Completed Green Belt Certification.
a Participated in Black Belt project reducing external PPMs from 55,000 to 0.
a Involved in Launch of Mercedes M-Class production / interfaced with APQP team,
awarded
a Responsible for product quality to Tier I / Tier II customers (including devel
opment of inspection criteria / work
instructions / SPC/inspection equipment development), involved with Launch Team
personnel (engineering / product / tooling / process / supplied material).
a Responsible for 8D Root Cause analysis (identified component design stack-up t
hat resolved customer PPMs).
a Responsible for PPAP approval of purchased components (molded plastics / metal
stampings) and creation of PPAPs for product supplied to customers.
a Participated in prototype sample builds.
a Performed D.O.Eas / statistical process capabilities.
a Facilitated PFMEA Kaizan programs.
a Involved in VA/VE seminars.
Quality Engineer 2001 - 2002
Pridgeon & Clay, Inc. - Grand Rapids, Michigan
a Responsible for product APQP quality functions, development of Process Flow
Diagrams / FMEAs / Process Control Plans for metal stamping.
a Direct interface with customer SQE for product launch and support.
a Involved in Die Shop tooling approvals.
a Development/implementation of 8D corrective actions (external / internal).
a Responsible for Tier 1 / Tier II PPAP submissions (heavy metal stamping - auto
motive body /
exhaust components).
a Interfacing with external / internal cross - functional teams.
a Developed inspection equipment / inspection instructions and worked with CMM p
ersonnel for program development.

Supplier Development Engineer 2000 - 2001

Jabil Circuits - Auburn Hills, Michigan
a Resident Engineer on site interfacing directly with customer Supplier Quality
Manager.
a Developed supplier quality measurables (audit ratings / NCMRs / PPMs / SPC).
a Created databases for supplier monitoring / procedures for PPAPs / Process Sig
n - Offs.
a Performed 2nd Party supplier audits per QS-9000 Standards.
a Approved supplier component PPAPs (electronics / light metal stampings / molde
d plastics).
a Interfaced with external / internal cross-functional teams.
Supplier Development / Quality Engineer 1997 - 2000
Robert Bosch Corporation - El Paso, Texas
a Instrumental in the development / writing of the Bosch North American Automoti
ve Supplier Corporate Quality Manual.
a Involved in Supply Chain Management / Supplier Sourcing Commodity Teams.
a Performed 2nd Party supplier/internal audits per QS-9000 / VDA Standards.
a Bosch certified Internal Auditor.
a Responsible for the quality of purchased components (aluminum die cast housing
s / light metal stampings / injection molded plastics), including monitoring of
supplier quality measureables (audit / corrective action / NCMR / PPM / PPAP app
roval / SPC).
a Interfaced with Design Engineers / Purchasing and other cross - functional tea
m members.
a Involved in supplier APQP development / tracking.
a Created / implemented ISO / QS - 9000 procedures.
a Created procedures / performed Supplier Process Sign - Offs.
Supplier Quality Engineer 1996 - 1997
GE CapCom - Juarez, Mexico
a Responsible for quality of purchased components (extruded aluminum casings / l
ight metal stampings / injection molded plastics for electrolytic capacitor asse
mblies).
a Transitioned the Supplier Quality role from Process Engineering to Supply Chai
n Management focus.
a Developed the supplier quality system (audit ratings / NCMRs / PPMs / SPC) and
writing of the Supplier Quality Manual.
a Performed 2nd Party supplier audits per ISO / QS-9000 standards.
a Involved in 8D corrective actions / supplier process improvements (reduction i
n dented casing PPMs).
a Responsible for purchased component PPAP approval.
a Development of Gage R&R / Receiving Inspection criteria.
a Involved in Six Sigma / D.O.E. analysis.
a Interfaced with external / internal cross - functional teams.
Senior Divisional Quality Engineer 1989 - 1996
United Technologies Automotive - El Paso, Texas
a Advanced from Materials Analyst to Senior Divisional Quality Engineer.
a Responsible for Divisional Quality support of wire harness manufacturing facil
ities (Juarez, Mexico / Chihuahua, Mexico), including daily involvement in manuf
acturing of six sites.
a Interfaced with O.E.M. Design / S.Q.E personnel for new vehicle launch program
s / follow - up programs / on - site supplier support (Grand Cherokee program fr
om prototype through launch phases).
a Team member awarded the Chrysler Silver Pentastar (cost savings of $500,000.00
at O.E.M. assembly plant).
a Developed / delivered presentation to Vice President of Jeep Truck Engineering
.
a Served as Key Team Member for implementation of QS - 9000 (Divisional / Plant
Level I - IV procedures).
a Involved in Q.O.S. / T.O.P.S. / QFDS / APQP / Ergonomic and VA/VE teams.
a Developed / delivered presentations (Hoshin Planning / 8D Corrective Actions /
Japanese Cultural Seminar and Flow / FMEA / Control Plan documentation).
a Involved in 8D / 7D corrective action reviews.
a Performed quarterly internal audits, supported 1st and 2nd party customer audi
ts (Ford / Chrysler / QS-9000 formats) and 2nd Party supplier audits per QS9000.
a Managed gauge calibration for Mexican Operations.
Market Analyst / Material Logistics Coordinator / Technical Support 1983 - 1989
Electronic Manufacturing - El Paso, Texas
a Involved in contract negotiations / production scheduling / material logistics
and customer interface.
a Developed market forecasts.
a Developed technical product catalog.
a Coordinated sample programs (analog potentiometers for commercial / military a
pplications).
a Key member involved in the development of sales / technical catalogs.
a Involved in the development of Quality Circles.
a Developed / delivered training seminars (product / new employee training).

EDUCATION
University of Texas at El Paso, El Paso, TX
Marketing - Focus in Logistics, Research, Analysis
ADDITIONAL ACTIVITIES / EXPERIENCE
a TS161949 - 3rd Party Auditor Certification - BSI
a ISO9001- 2008 3rd Party Auditor Certification - BSI
a ISO20252 - 3rd Party Auditor Certification - BSI
a AS9100 AA - 3rd Party Auditor Certification - BSI / RABASQ
a Performed 2nd Party / 3rd Party Internal Audits per Ford Q1, ISO 9001:2000, QS
9000, TS16949 Standards
a Green Belt Certification
a Proficient in APQP / FMEA development
a 5-Why / Kepner-Tregoe / Shanin / T.O.P.S. problem solving techniques.
a 5 S / Kaizan / KanBan / Lean Manufacturing / DOE / GD&T / GR&R concepts
a Proficient with SPC software / Windows Office programs / Microsoft Outlook / L
otus Notes.
a Dale Carnegie Program (including 2 Certificates of Recognition