Education:
B.S. Materials/Metallurgical Engineering, University of Cincinnati, 1984. Participated in Co-Op Program.
M.B.A. Xavier University, 1992
Completed 3 week course of "Quality Through Productivity and SPC" from the University of Tennessee. Refractory course presented by the Orton Foundation. AIAG internal auditor training, QS-9000 and TS-16949 training. Computer proficiency includes MS Word, Excel, Visio, PowerPoint, Access, MiniTab and RSView. Level 1 Thermographer. Green Belt Trained
Experience:
AMG Vanadium - Cambridge, OH. Sr. Process Metallurgist (4/06 – 6/15)
• Process metallurgist for EAF shop producing ferro-alloys.
• Ensure melt shop operations follow procedures to meet customer quality requirements.
• Lead for several design and engineering capital projects completed on time and within budget.
• Responsible for all refractory and coatings selection, ordering and installation projects for the melt shop.
• Optimized EAF power controls and practices resulting in a 6% productivity increase and 15% better power utilization.
• Dealt directly with suppliers of various consumable materials to reduce consumption and costs.
• Tracked usage and cost performance of consumable materials and reported these to the accounting dept..
• Worked with cast iron foundry suppliers on failures and design changes to improve casting life by 11%.
• Employed use of Thermal Imaging to reduce furnace delays and savings of $300K/year.
• Complete responsibility for the production, toll processing and profitability of FeNiMo alloy. Developed slag recycling process to recover 5% of lost metallics.
• Initiated the collection of process and delay data to Pareto top delays for KPI tracking and process improvement projects.
• Responsible for hiring and supervising college interns and scholarship awards.
• Created and maintained Standard Operating Procedures.
• Hosted 3rd party ISO assessments for the melting department.
• Managed all vanadium bearing raw materials to optimize slag chemistry, metals recovery and finished goods properties.
• Visited customers to understand their usage and performance of our products.
• Worked with Lean Management techniques, continuous improvement activities, 5S and Kaizen events.
• Recently assigned as melt shop supervisor in charge of 12-15 employees.
Lear Corp - Zanesville, OH. Quality Engineer (12/03 – 3/06)
• Ensure production operations and engineering follow procedures to meet customer specifications and requirements.
• Involved with new product design launches by completing many assigned program management deliverables.
• Monitor, problem solve, and mistake proof circuit board and switch production operations.
• Reviewed, approved or rejected supplier submitted PPAP's.
• Develop and write new standard practices or update existing practices.
• Participated on APQP projects and developed FEMA's, Control Plans, Process Flows, Process Capabilities, GRR studies and for TS-16949.
• Utilized SPC and MiniTab software for problem solving and trouble shooting.
• Responded to customer concerns and rejects using the 8D and 5P problem solving processes and methods.
• Worked with testing lab to perform life cycle testing and dimensional verification.
• Visited customer plants to review problems and report on root cause and implemented corrective actions.
• Coordinated part sorting and containment activities upon receiving notice of a customer issue.
• Compared dimensional layouts and testing data with customer blueprint drawings and written specifications.
• Collect and summarize quality data to Pareto top defects for process improvement projects.
• Attended Lear sponsored Lean Six-Sigma training course for Green Belts..
• Develop knowledge of surface mounted components; wave soldering, solder paste and paste reflow, and IPC standards.
AK Steel - Zanesville, OH. Senior Process Control Engineer (12/98 – 10/03)
• Establish unit operating parameters for key process variables.
• Monitor, problem solve, mistake proof and optimize annealing operations to assure that production processes are
capable of producing in accordance with customer specifications. These efforts contributed to meeting plant goals of
reducing diversions by 27% and reducing customer claims to less than 1000 ppm.
• Investigated, justified, purchased and implemented the use of various automated and portable measuring systems.
• Worked with batch and strip annealing processes which use controlled atmosphere furnaces to achieve product properties.
Darryl J. Douglass
AK Steel – cont’d:
• Received award from AK’s CEO for developing new practices to increase production capacity by 30%.
• Used DCS and Wonderware process control system to improve heat treat cycles and product quality.
• Coordinated efforts to maintain the annealing department’s QS-9000 certification and participate in QS-9000 and
TS-16949 audits. Also conducted internal audits of other departments.
• Managed new process projects and existing process improvement projects.
• Problem solved strip coating processes and reduced diversions by 50%.
• Worked Shift Supervisor position as needed.
AK Steel Supervisor Inspection / Testing Departments (9/95 - 12/98)
• Supervised 25 hourly inspectors and lab technicians. Responsible for employee safety, schedules, overtime and training.
• Lead A2LA accreditation for magnetic testing lab through third party on site audits and report results.
• Directed the analysis of product quality and diversions of all products processed.
• Investigate customer claims to determine responsibility, implement corrective actions and identify areas for continuous
improvement.
• Participated in diversion reduction team resulting in $1 million per year cost savings.
• Possess a working knowledge and conceptual understanding of statistics and SPC ...
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