Joseph Rehall / Professional experience

Process improvement, quality, operations & software

Warranty departments at Nikola and Cruise, warranty audits and applications at Audi.

I’m Joseph Rehall, a Lean Six Sigma Black Belt based in Arizona. My background spans two decades in process improvement, quality, and engineering. I’ve established departments, developed operating procedures, managed warranty and audit work, and built software around the problems I’ve worked through firsthand.

Background
20 years in process improvement, quality, and engineering
Credential
Lean Six Sigma Black Belt
Location
Arizona, United States

Where my experience fits

I’m interested in the whole problem. A quality issue may need a supplier investigation, a clearer procedure, or a better way to track the evidence. An operations problem may need someone to follow the handoffs and find out where the work stalls. Sometimes the missing piece is software, and I can build it.

That combination fits continuous improvement and operational excellence, quality operations, business systems, and software automation. I bring experience carrying out the work as well as building the procedures and applications behind it.

Where I’ve put that into practice

These are examples of the responsibilities I’ve owned and the systems I’ve developed. The settings differ, but each called for understanding the details and making the work easier to manage.

  • Audi of America

    At Audi, I review warranty claims alongside repair orders, technician notes, and labor records. I designed and developed Audi Nuvobook and Audi Team Dashboard. Nuvobook connects audit execution, automation, and risk profiling. The dashboard brings audit results together for management and executives, then feeds findings back into Nuvobook to improve the logic behind future audit planning. I also configured a Microsoft Copilot agent to support Audi’s warranty audit process using its SPREAD AI tool.

  • Nikola Motors

    I built the warranty and supplier warranty cost recovery departments, establishing processes for dealer claims and supplier recovery. I wrote dealer procedures, defined compliance KPIs, adjudicated claims, and audited repair times, costs, labor codes, and policy compliance. I worked with engineering, procurement, and production to address supplier quality issues.

  • General Motors / Cruise

    I built warranty and supplier warranty cost recovery departments for the Cruise Bolt and Cruise A100 Origin programs. I established claim submission and adjudication workflows within GM’s Global Warranty Management System. I also developed an ISO 9001-aligned quality management system and corrective-action processes, audited company processes as Lead AMS Auditor, and coordinated supplier parts reviews to investigate failures and determine responsibility.

  • Lucid Motors

    I built systems to track EV powertrain failures and report issues to suppliers through Non-Conforming Material Reports (NCMRs) and Corrective and Preventive Action (CAPA) reports. I investigated failure modes, tracked nonconforming components, and coordinated root-cause analysis and corrective actions with suppliers and engineering.

  • Nissan, through AiM

    I built applications for an Android phone toolkit designed to help approximately 1,000 inspectors and auditors work more efficiently and solve field problems. My dealership and field audits covered warranty and insurance claims, repair estimates, recall compliance, asset verification, and financial reconciliation. I also trained new hires on field audit procedures.

From the cause to the corrective action

My Lean Six Sigma Black Belt background shapes how I approach a recurring problem. I start with a recent example, follow the records, and compare what happened with how the process was intended to run. I want an explanation that stands up to the evidence.

I’ve written standard operating procedures, set up key performance indicators, and built systems to support that work. A procedure needs to be clear enough to use. A measure needs to tell the team something they can act on. A corrective action needs a way to check whether it addressed the original problem.

I build software with the work in mind

My audit applications grew out of tasks I knew firsthand. I wanted the records, review logic, findings, and reporting to work together. That experience guides how I develop software: follow the task, make the rules clear, reduce repetitive handling, and keep exceptions visible for the person who needs to resolve them.

I have some experience with PostgreSQL and prior experience with C#, .NET, and WPF. In my own projects, I configure and test local language models with development assistance from Codex and Claude, running Qwen, Gemma, and Mistral through Ollama. I like trying an idea, checking what it does, and working through the parts that need improvement.

I also design and develop websites, work on hardware prototypes, and have helped build a multi-million dollar business. That broader experience keeps the technical decisions connected to the business and the people using what I build.

A few useful answers

What kinds of roles fit your background?

Roles that connect process improvement, quality, operations, and systems are a strong fit. My experience includes supplier quality, warranty and claims, audit programs, department development, and software automation. I’m interested in understanding the responsibility and the problem the team needs someone to own.

What is your Lean Six Sigma background?

I’m a Lean Six Sigma Black Belt. I apply that background to root-cause investigations, corrective action, operating procedures, performance measures, and the systems teams use to manage their work.

Where can I see examples of your work?

My portfolio includes Audi Nuvobook, Audi Team Dashboard, and a collection of websites and research catalog brands. The capability pages explain how I approach audit systems, software, process improvement, and hardware. I’m happy to walk through the decisions behind a project.

Let’s talk

Let’s talk about the work

If you’re hiring, send me the role and what your team needs to accomplish. I’m happy to discuss where my experience fits and walk you through relevant work.