Process and Quality Control Solutions LLC

I’m Dave Lehrschall. I’ve started this consulting business because I thoroughly enjoy working with teams to solve process and quality problems. Process and Quality Control Solutions LLC has only one employee, me. I’ve gone through the exercise of formally setting up this business so that I may qualify to work with Automotive O.E.M.’s, their suppliers, and similar businesses.

Process and Quality Control Solutions LLC is a certified organization by the State of Indiana. I have established federal and state tax identification numbers. I have also acquired General Liability and Professional Liability insurance to work as a consultant. “Bonding” does not apply because I am an insured owner-operator directly covered by the liability policies.

Training and Certifications

M.S. in Manufacturing Management – Kettering University

B.S. in Computer Science – Park University

Mechanical Engineering study at General Motors Institute

Four year Journeyman Tool and Die-maker apprenticeship

Aircraft Maintenance Officer – U.S. Army

Professional Experience

I was a Chief Manufacturing Engineer at General Motors’ Delphi Automotive Division with responsibilities for the development and management of automotive component processes and controls around the globe. I was promoted to this position after a career that included work as a process engineer, product engineer, manufacturing supervisor, engineering manager, quality manager, and other assignments. We sold automotive components to Ford, Chrysler, BMW, Hyundai, Holden, Volkswagen, Daewoo, Harley-Davidson, Case, General Motors, and others.

I was a Quality Manager at Siemens. We produced circuit breakers, load centers, and switch gear products.

I was a Quality Engineer at Toyota Motor Manufacturing, Indiana (TMMI).

For two years I have been teaching TECH 103 Manufacturing Materials and Processes at the University of Southern Indiana.

Related Training and Certifications

  • Shainin Problem Solving Techniques
  • Taguchi Robust Engineering Methodologies
  • Juran Six Sigma for Manufacturing
  • NUMMI Toyota Truck Production Practices
  • ASQ Certified Six Sigma Black Belt
  • ASQ Certified Manager of Quality/Operational Excellence
  • ASQ Certified Quality Auditor
  • ASQ Certified Quality Engineer
  • ASQ Certified Supplier Quality Professional
  • Bilingual (fluent in English and Spanish)
  • Six-sigma Black Belt – University of Texas at El Paso
  • VDA 6.3 Standard
  • TS 16949 Standard

Quality Tools Experience

I have extensive experience using the following AIAG and Toyota Production System tools:

Process Flow Diagrams (PFD), Process Failure Mode Effect Analysis (PFMEA), Process Control Plans (PCP), 8D, 5Why, QPR, Supplier Quality Assurance Manual (SQAM), Statistical Process Control (SPC), Measurement System Analysis (MSA), Design of Experiments (DOE), Process Capability Studies (Cp and Cpk), Advanced Product Quality Planning (APQP), Lean Manufacturing, Continuous Improvement, Six Sigma, and other quality methods.

My Goal

I’ve been blessed and supported by many through the years. My goal is to share the skills I’ve learned with generations to follow. I’ve formally set up this business so that I may work with automotive O.E.M.’s and their suppliers.

My ASQ certifications’ status can be checked using the included link to the ASQ Certification Registry. Select “All Certifications”, “United States”, and enter “Lehrschall”.

You can review my skill’s endorsements at the included link to

Please contact me to discuss working on your Process and Quality Control Solutions.