John F Failing

US Army Veteran
Ph # 562 388 3947 / 616 589 3936
E Mail jfailing05 @ yahoo
. com

Executive Summary
Innovation| Leadership | Integrity
A proven leader with a strategic vision. As Managing Director of Quality and Engineering supporting
world class organizations like Boeing, GM and Ford, I have been able to share my broad
knowledge in Quality, Engineering, Test & Validation, and Lean Manufacturing principles. I have lead
the efforts in developing and meeting the company's objectives through the utilization of quality
focused systems, goal driven practices, and a solid foundation in contract quality engineering.
Championed R&D & risk mitigation using FMEA, RCA & DVP&R, to best meet customer and
design deliverables. Led team efforts to contain costs while conforming to the best interest of
shareholders, customers, employees, and the general public

Areas of Expertise
Strategic / Tactical • Auto/Medical / Energy
Planning & Budgeting Aerospace APQP GD&T
• TS 16949/ ISO 9002 • R&D Electronics System
13485 & AS9100 Rev• D • Hybrid & Fuel Cell
• Correct Action /FMEA Processes & Controls
PPAP APQP/ Warranty • Supplier Development
• Engineering Management/ Design
Validation / Risk Assessment
• Multi-million Dollar Research
• RCA / SPC / Document Control &
Change Control / QMS Management
• Fluid Dynamics / Chemical Systems

Fletcher Engineering- Quality and Engineering Manager /Supply Chain Manager / Opns/ HSE Dir.
Supporting Intelligent Energy /GM Powertrain Supporting GM Truck & Bus, Boeing Airbus, SpaceX
Jan 2010-Present

Lead the quality , engineering, operations, & supplier development engineering groups for the
research of NG reformation to Hydrogen and fuel cell applications for aerospace, automotive, and
commercial systems. Designed process delivery and control systems for all applications, including
Energy storage systems, generators, & chemical plants.. Based on data collected in lab experiments & pilot
plant operations. designed & manufactured H2 reformation processes to separate components of liquids &
gases to generate electrical currents using controlled fluid dynamics. Personally designed fluid, water, and
wastewater delivery systems in all applications. Headed team tasked with creating the manufacturing
process for fuel cell module assembly for commercial applications across product lines, as well as site
Specific applications unique to facility requirements. Over site of control systems.
In cooperation with Boeing, designed and built the 1st 100% fuel cell powered aircraft.
Partnered with Boeing, Airbus, and Lockheed on design & implementation of fuel cell applications in
commercial and military vehicles & aircraft. Engineering & validation test experience for all
electronic converters, controllers and connectors in process development/ corrective action / root
cause analysis / manufacturing engineering experience that utilizes fuel cell technology. Oversight of
design, development, launch and manufacture of fuel cell powered generators in India in partnership
with Air Liquide. Championed my facilitycertification to ISO 9002, ISO 13485, AS9100, TS16949
 • Evaluate four green energy programs with sales of 26 million dollars in annual revenue.
Insure consistency with defined government regulations. Champion fuel / fluid delivery
systems design, customer facility integration and CE certification.
• Championed improved documentation and communication processes, improving timing
& deliverables. Developed standardized work instructions to ensure consistency in execution.
Designed fluid delivery systems for all applications. Led the manufacturing & supplier
development engineering for the creation of a battery manufacturing plant assembly process,
complete process review, & first article execution. Championed AS9100 / ISO 9002 compliance
efforts for Boeing, Airbus, & Lockheed fuel cell projects. Additional engineering
responsibilities including T&V, failure analysis, government regulation review, &material
specification / certification. Designed fluid delivery systems for all applications. Facilitated
implementation & maintenance of the QMS (AS9100/ISO9002/ISO13485 & TS 16949).

Accomplishments: Intelligent Energy /GM

• Insure cross functional organizations have adequate facilities, required equipment, staffing
and financial resources to meet program specific deliverables. Insure compliance to govt.
safety and environmental regulations. Removal of roadblocks inhibiting timely completion of
deliverables. to meet an average budget of $ 20 million US.
• Managed four green energy programs with 26 million dollars in annual revenue, to insure
consistency with defined government regulations. Spearheaded Engineering Design Risk
Assessment [DFMEA] and Review of fuel cell applications & natural gas to hydrogen / CO2
reformation [FMEA]. Champion QMS AS9100/ISO 9002, ISO 13485 and TS 16949& CE
certification efforts.
Fletcher Engineering (General Motors)- Supplier Quality Engineering Manager.
May 2007 to Jan 2010
Led the supplier development engineering efforts for the creation of the battery systems for the
Chevy Volt, GM Truck & Bus, (Hybrid Bus) and fuel cell vehicle applications. Specified requirements
and qualified potential suppliers of electro-mechanical and electronic controls systems and their
designs, reviewed & approved manufacturing plant facilities, and final design of the battery system,
process and first implementation execution of battery system production. Vehicle / Powertrain
system integration.(Volt, Truck & Bus) Engineering & validation test experience in process
development/ corrective action / root cause analysis / manufacturing engineering experience that
utilizes/develops advanced battery or fuel cell technology /CNC & formed manufacturing
engineering, manufacturing process for battery module assembly, including advanced batteries (Li-
Ion, NIMH, fuel cells) the hybrid battery systems, as well as the battery coolant fluid systems.
Certified SQM - Supplier Quality Manager, NPL (New Product Launch) and APQP/PPAP
GM.
• Insure cross functional organizations have required equipment, staffing and financial
resources to meet program specific deliverables., removal of roadblocks inhibiting timely
completion of deliverables. to ensure an average budget of up to 40 million dollars/per
potential supplier.
• My battery team's efforts were recognized as contributing greatly to the Volt being the most
seamless, successful launch of a new vehicle in GM history. The present battery system is
recognized as the safest hybrid battery system in the industry.
• Audited & trained suppliers to AS9100 Rev D for GM, Honeywell, GE, and Intelligent Energy
 Joined GM Truck & Bus / Volt programs, thru Fletcher Engineering, after the launch of the Ford
Escape Battery System was completed (Post Sanyo). Transitioned to fuel cell research and development
in 2010.

Sanyo Energy Corp: (Direct) Quality/Engineering Manager & Program Manager

Sept 2005- to May 2007
Managed test and laboratory departments for all battery program testing (vibration, life cycle, crash, SOC)
& corrective action / root cause analysis including all hardware, software, electronics, systems
integration (breadboard) & R&D for Li Ion and NiMH hybrid, plug-in hybrid, and fuel cell vehicles. As
Engineering Manager, I led the coordinated effort of engineering of AC/DC converters, regenerative
braking systems, power controller & conductor/cabling designs, and mating components. Insured that
Sanyo designs incorporated the latest in battery systems, battery coolant systems, and energy storage
technology. Through key leadership of the battery engineering group at Sanyo, we achieved significant
savings through design, staffing, procedural and process improvements.
• Spearheaded Sanyo Corporation from one of the lowest rated suppliers on Ford’s supplier
evaluation ratings to a successful launch of the Escape hybrid within the 1st 18 months of program
initiation. Successfully lead and implemented TS16949 efforts at all Sanyo facilities, and
championed quality efforts to insure continued registration compliance. Trained staff in the
principles of 8D, change management and document control.
• Facilitated engineering implementation and maintenance of the quality systems (AS9100 / ISO 9002
and later TS 16949, all launch functions (DFMEA, PFMEA, PPAP), tooling design & verification,
electrical / electronic engineering, prototyping, gauges & fixtures, documentation review, approval, &
submissions, supplier quality & supplier’s evaluations, technology review, writing specifications
for all energy storage units.
•
Fletcher Engineering (Ford Motor Company), Supplier Quality Development: Ford Escape Hybrid.
Sept 2003 to Sept 2005
Specify, qualify and manage supply base to insure compliance to Ford quality standards, approve APQP/
PPAP qualification , conduct capability studies at suppliers, work with design engineering on vehicle
powertrain integration, manufacturability, delivery, storage, and warranty concerns. Certified Launch,
APQP / PPAP expert.

Fletcher Contract Engineering Services: Quality Manager: Automotive, Medical, & Aerospace.
Mar 2002 to Sept 2003
Managed test and quality departments validating in the areas of electronics, chemical processing, injection
& blow molding, finishes, stamping, interior systems, lighting and bumper systems, electroplating,
adhesives, & investment castings. Similar improvements at other assignments, up to 26%, resulting in
streamlining of contract review, manufacturing, design, R&D, quality, corrective action / root cause
analysis test, & approval processes. Gained A2LA / GM accreditation & certification for seven separate
testing labs. Championed NADCAP and ITAR certification S& qualification efforts. Certified APQP /
PPAP / 8D / PFMEA / DFMEA expert at both GM & Ford.
Lear Siegler / Smiths Aerospace
May 1996 to Mar 2002
QA / Materials Engineer: Responsible for materials specification, review, test & verification. failure
analysis, NDT, circuit board & semiconductor test & validation, metallurgical testing, SEM, MRB, plating
chemical process & analysis. Quality engineering: Responsible for overall integrity of circuit board /
electronic assemblies, ESD, DLA reporting, solder to Mil 2000 & assembly quality to Mil 9858A, flight/fuel
management system test, final release approval.

Achievement Summary while at Fletcher Engineering

Manager of Engineering, Quality, & Laboratories : Automotive / Aerospace / Medical Fields

Intelligent Energy LLC(2010-Present), CPC Inc., Honeywell, GE, II Stanley, ASC, Theirica, Rayco, Hilco
Technologies (92-99) Energy Corporation (02-04) Engineering / Quality / Test Lab department supervision /
management/ reporting, QS 9000 systems to include implementation, supplier quality development, Scrap /
PPM reduction and performance tracking, ISIR / PPAP submission, prints, tolerance (GD &T), chemical
process improvement, customer liaison, lab certification. SPC / Warranty / validation, process validation, all
aspects of process, product, and program risk assessment, performance, and in process testing, semiconductor
& circuit board test and design. Championed efforts of transplant engineering & quality department (13
months), reducing scrap & improving process / return costs by 20%, annual savings $550.000. Facilitated
engineering implementation and maintenance of the quality systems (QS / ISO 9000/MIL 2000C, 9858A and
later AS 9100 & TS 16949), all launch functions (DFMEA, PFMEA, PPAP), tooling design & verification,
electrical / electronic engineering, prototyping, all CNC operations, gauges & fixtures, documentation review,
approval, & submissions. Certified APQP expert at both GM & Ford. Supplier Quality Development
Manager: Regenerative Energy / Automotive Powertrain Systems/Hybrid Battery Systems, Fuel Cells GM
Power Train Group; Battery & Fuel Cell Systems (04 -10) Ford Motor Company: Escape Hybrid (99-02)
Responsible for supplier development, QS 9000, ISO9002, ISO 13485 & AS9100 compliance/ performance
evaluation. PPAP / FMEA, change control and engineering training.

QS / ISO 9000 / AS9100 Cert Lead Assessor: Entela QSRD QMS Systems (1999)
Performed audits to QS & ISO standards. Advised / consulted clients on how to pass audits / implement
quality systems. Certified approaching 100 clients to ISO 9001, 9002, 13485, TS 16949 & AS9100D. Supplier
Quality Development training, and sub supplier evaluation & training. QMS system training,
implementation auditing and certification.

Quality, Process Engineer/ Lead Engineer: Automotive / Aerospace / Medical

FKI, American Metals, Howmet, US Horizon. Hildebrand Medical (92-99) Quality Engineering, QS 9000
Systems, lab accreditation(A2LA), program management, SPC, CMM Layout / 1st Article, GMP, DFMEA,
PPAP, APQP, circuit board, semi con and end system validation testing, design & review, CNC machining &
approval, fixture & tooling design, verification, and review, Test parameter establishment & certification,
Supplier Quality Development & Assessment.
EDUCATION
US Army, Signal Corp Microwave Electronics & Communications Training 2 years
BS Chemical Engineering- Michigan State University, Lansing, MI 1985
Lear Siegler Aerospace MIL STD 2000 MIL Q 9858A, TQM, JIT / Taguchi Methodology 5 yrs.
Bachelor of Arts, Degree in Business Admin - Jordan College, Reed City Michigan 1991
Perry Johnson - CQE /CQM QS / ISO 9002 /TS 16949/ AS9100D Training, Cleveland, Ohio
Perry Johnson- Six Sigma Green Belt Certified
ENGINEERING COMPETENCIES
Administration / Quality / Engineering / Purchasing / Lab Management/Aerospace Systems /
Electronics / Electromechanical Systems Assembly & Design/Automotive Applications (OEM) /
Tier 1 Program Management/Battery Systems (NIMH, Li Ion)Design, Test, Systems Integration,
Supplier Management and R&D/CADCAM / AUTOCAD 13 / Design / R&D/Product
Launch/Chemical Coatings / Finishes / Applications / VOC’s / Color Matching/Chemical Process/
R&D/Engineering / Analysis /CMM /CNC Machining / Layout / 1st Article
Submission/Continuous Improvement Methods (Kaizen)/Control Plans / DOE / PFMEA / DFMEA
/ PSW / PPAP Submission & Approval/Electrochemical Analysis / Wet Chemical
Analysis/Electromechanical Systems, Semi-Conductor & circuit board test & validation
/Automotive & Aerospace/Electroplating Lab Management/ Lab View / Engineering - Plastics ,
Zinc , Steel / Electronics / Electromechanical system design/Failure Analysis - Electronics,
Electromechanical, Process, SEM, /FDA/ GMP/ DNR / EPA / OSHA / NRC / MIOSHA Compliance,
MSDS /Fuel Cell Technology / Hybrid Vehicles / Hydrogen power plants / Power Grid
Integration/Gas Chromatograph / Mass Spec. Operation, Maintenance, Training/Health & Safety
Management / Industrial Hygiene / MSDS Applications, High Voltage Batteries / Hybrid Battery
Systems / Vehicle Powertrain Integration/Hybrid vehicle & battery (NiMH and Li Ion) and
powertrain systems./Japanese / German / French Transplant Experience/JIT / TQM / Taguchi /
Team Building Training, & Implementation/Laboratory , Test Qualification , Setup / Management
/ Design / Training/Lighting Systems - Headlamp / Tail lamp – Automotive/Materials
Specification / Testing / Evaluation / R&D / Warranty Review/Metallurgical / Physical & Chemical
Testing /Specification & Lab / Procedure Training/Non Destructive Testing / Vibration / Life
Cycle Testing/Photometric Testing - Automotive Lighting Systems/Production Supervision -
Automotive / Electronics / Chemical/Program Management Product Launch - Automotive /
Aerospace / Chemical /QS / ISO 9001,9002 / TS 16949 /AS9100D Systems / Coordination / Auditing
/ Training/Quality Assurance Management & Engineering Training & Implementation/Research &
Development - Aerospace / Automotive / Chemical Supplier Quality Development / Vendor
Certification / Systems Training & Supplier Performance Review/Test Equipment Calibration /
Repair / Training & Operation/Zero Defect (6Sigma) Program / Management & Implementation
Truck and Bus hybrid / electrification to include conversion / modification of existing platforms.

Professional & Charitable Organizations and Affiliations

Habitat for Humanity

American Society for Quality Control
American Society of Metallurgists
American Society of Materials Engineers
Pacific Maritime Charities, Long Beach, CA
Ronald McDonald House, Long Beach, CA
American Cancer Society, Stand Up to Cancer
Duke Foundation, Dana Point CA
Veterans Outreach

REFERENCES WILL BE PROVIDE UPON REQUEST