Rodney Walker
Eltham North,VIC
Summary
Proactive Quality Engineer with extensive experience in developing inspection plans, resolving non-conformance issues, and conducting compliance audits. Proficient in quality processes, control plan development, and root cause analysis. Bringing a strong attention to detail and problem-solving skills to ensure adherence to industry standards and improve customer satisfaction.
Overview
31
31
years of professional experience
Work History
Quality Engineer
Boeing Aerostructures Australia
07.2022 - Current
- Developed inspection plans based on design specifications, ensuring all critical requirements were verified throughout the manufacturing process.
- Improved customer satisfaction levels with timely resolution of non-conformance issues and effective corrective actions.
- Performed quality inspections and drafted reports to detail non-conforming material issues.
- Conducted process compliance audits and preparing reports which detailed corrective actions and continuous improvement opportunities.
- Contributed to root cause analysis to determine core reason for failures and errors.
- Product Acceptance Software and Qualification plan/report documentation prepared for Zimmermann 5 axis NC machine.
Project Manager
APV Testing
11.2020 - 07.2022
- Successfully planned, designed, and scheduled phases for a global OEM test program. Delivery of 10 development vehicle crash tests and achieving customer timing and reporting requirements.
- Capital equipment specification definition, evaluation, sourcing, quotation, international freight, installation, safety and commissioning.
- Strategic resource planning and execution.
- Procedure development.
- Customer liaison, status updates and reporting.
- Team communication, roadblock removal and requirement clarification.
- Technical report writing in accordance with NATA, ANCAP and FMVSS/ADR/ECE regulatory protocols.
- Met project deadlines without sacrificing test quality or workplace safety.
Advanced Vehicle Design - Body Structure
Holden Ltd
03.2020 - 06.2020
- Lead engineer in cross functional team consisting of cad designers, manufacturing, design studio, FEA and interfacing engineers to produce math data for advanced vehicle structure design achieving program timing.
- Risk assess design direction utilizing extensive validation experience.
- Liaise with cost engineering to estimate component and tooling cost impact and track to program budget.
Validation Engineer
Holden Ltd
08.2008 - 02.2020
- Strategic planning and development of finite element analysis (FEA), component, sub-system and vehicle test, verification and validation plans for concurrent programs.
- Analyze and document test evidence in verification and validation cross-reference matrix for system durability, fatigue, structural performance and test standard compliance.
- Identify resource and budget requirements.
- Project manages validation execution and overcome threats to achieve plans.
- Conduct validation sign off for documentation for Production Part Approval Process (PPAP).
- Regulatory compliance for local and export markets.
- Designed and implemented the 2013 model year large car body structures and closures validation plan ($22M) to meet program quality, reliability and timing requirements. Cost saving approximately $600k achieved through optimizing usage of available test properties.
- Achieved validation sign off in a compressed time frame for multiple parts impacted by a plastic raw material resource. Multi million dollar losses in revenue due to assembly plant shut down were avoided.
- Achieved validation sign off for 37 new accessories for the 2017 Colorado mid size truck, which increased accessory sales revenue by 48% to $1,989 per vehicle.
Design Release Engineer
Holden Ltd
01.2006 - 07.2008
- Lead engineer to design, release and validate sheet metal stampings per program and regulatory requirements.
- Enhanced product design by consistently collaborating with cross-functional teams and addressing feedback.
- Proactively identified risks associated with design changes and developed mitigation plans to minimize negative impacts on overall project timelines.
- Increased customer satisfaction with streamlined designs that focused on ease of use and functionality.
- Achieved timely delivery of projects by successfully managing resources, budget constraints, and stakeholder expectations.
Continuous Improvement Engineer
Holden Ltd
10.1999 - 12.2005
- Lead product warranty investigations in conjunction with suppliers and assembly plant to determine root cause and solution implementation for product improvement and warranty expense reduction.
- Reduced Pontiac GTO warranty by US$47/car by solving windscreen wiper blown fuse problem. Total program benefit: US$1.8M.
- Significant warranty reduction for radio systems through optimizing software. Improved functionality reduced warranty cost by $500/claim and improved customer satisfaction.
Team Leader - Structures Laboratory
Holden Ltd
01.1998 - 09.1999
- Lead a team of 7 engineers (6 mechanical and 1 electrical) to execute incoming laboratory test requests.
- Set performance expectations for the team, monitoring progress towards goals and providing constructive feedback as needed.
- Empowered team members by delegating responsibilities according to individual strengths and areas of expertise.
- Maintain NATA accreditation.
- Capital Project business case preparation. Director approval achieved for $1M laboratory test equipment business case submission.
- Assist manager with budget preparation.
Mechanical Test Engineer
Holden Ltd
05.1994 - 12.1997
- Independently carry out assigned test requests and document results in a technical report.
- Develop test procedures to support ISO9001 Quality System implementation.
- Developed new laboratory test methods for panel dent resistance performance after returning from an investigative trip to General Motors Detroit (1997).
- NATA signatory for laboratory mechanical testing accreditation.
- Data acquisition and analysis.
Education
Certificate - Auditing A Quality Management System ISO9001:2015
SAI Global
Melbourne, VIC11-2022
Certificate - Design For Six Sigma - Black Belt
General Motors
Melbourne, VIC04-2015
Certificate - Design For Six Sigma - Green Belt
General Motors
Melbourne, VIC11-2013
Bachelor of Engineering - Mechanical Engineering
Royal Melbourne Institute of Technology
Melbourne, VIC06-1994
Skills
- Control Plan Development
- Quality processes
- Non-conforming material reports
- Root Cause Analysis
- Minitab Statistical/Process Capability Analysis
- Technical Report Writing
- Regulatory Compliance
- MS Word, Excel, PowerPoint, Project
- Lead Auditor
- Mentoring and Leading Teams
Timeline
Quality Engineer
Boeing Aerostructures Australia
07.2022 - Current
Project Manager
APV Testing
11.2020 - 07.2022
Advanced Vehicle Design - Body Structure
Holden Ltd
03.2020 - 06.2020
Validation Engineer
Holden Ltd
08.2008 - 02.2020
Design Release Engineer
Holden Ltd
01.2006 - 07.2008
Continuous Improvement Engineer
Holden Ltd
10.1999 - 12.2005
Team Leader - Structures Laboratory
Holden Ltd
01.1998 - 09.1999
Mechanical Test Engineer
Holden Ltd
05.1994 - 12.1997
Certificate - Auditing A Quality Management System ISO9001:2015
SAI Global
Certificate - Design For Six Sigma - Black Belt
General Motors
Certificate - Design For Six Sigma - Green Belt
General Motors
Bachelor of Engineering - Mechanical Engineering
Royal Melbourne Institute of Technology
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