Azmat Khan Email and Phone Number

• Single voice leader for total Program quality from program framework initiation to launch.• Develops & maintains QMS budgeting of $250M for new program tooling & measurement systems.• Early interface with design studio & product design to develop DTS and styling interfaces desensitization.• Develops & lead exterior, interior design interfaces, clay development & tabletop models for leadership reviews and buyoffs.• Works as a manufacturing & quality architects b/w design… Show more • Single voice leader for total Program quality from program framework initiation to launch.• Develops & maintains QMS budgeting of $250M for new program tooling & measurement systems.• Early interface with design studio & product design to develop DTS and styling interfaces desensitization.• Develops & lead exterior, interior design interfaces, clay development & tabletop models for leadership reviews and buyoffs.• Works as a manufacturing & quality architects b/w design studio, product design and manufacturing execution teams to achieve quality and manufacturing deliverables 20% above the targets of SPQRC.• Develops & manages quality and dimensional build targets at pre-production and launch in plant.• Develops upfront BOP and BOE tooling & fixturing strategies through critical interface meetings enabling 20% cost reduction with launch excellence quality targets above 70% at start of production.• Implements upfront DFSS glide path charting with sufficiency plans to achieve 70% reduction in GCA, IPTV & Warranty.• Manages CAE simulation to drive the development of product design math for as manufactured Vs as assembled.• Forging early strong partnerships with suppliers to understand their processes to mitigate the risk of parts variances. Leads supplier quality activities for PPAP, PDR & compliance to IATF 16949.• Leads supply chain management initiation of SPPS, containment action plans with cost recovery.• Develops suppliers training workshops for parts matching submissions and matching quality targets.• Prepares parts submission requirements before SOR releases & tooling kick-off at supplier sites. • Manages tech reviews with buyers & design release for sourcing. • Develops Gantt charts and leads slow build matching to meet tooling and gauging R&R.• Set up PVR reviews for Class-A surface defects resolution & buy-off using GSQE/GFQE applications.• Leadership management of salaried & hourly workforce for team building, mentoring, and training. Show less

• Developed and maintained Plan-for-every-part for New and MCE program launches.• Managed supply chain by creating tombstone charts and worksheets for budgeting and procurement of integration material.• Introduced batch changes criteria for least impact on launch timing, reworking and scrap resulting in 40% cost reduction.• Developed training workshops and forums to engage suppliers before and during launch milestones builds for Iterative matching.• Implemented innovative… Show more • Developed and maintained Plan-for-every-part for New and MCE program launches.• Managed supply chain by creating tombstone charts and worksheets for budgeting and procurement of integration material.• Introduced batch changes criteria for least impact on launch timing, reworking and scrap resulting in 40% cost reduction.• Developed training workshops and forums to engage suppliers before and during launch milestones builds for Iterative matching.• Implemented innovative concept of early first shot parts mini matching at supplier’s sites for dimensional iterations loops.• Developed histograms and pareto charts to prioritize parts matching issues and identified top variance contributors. • Introduced early design virtual simulation to detect part design interferences resulted in cost saving of above $20M. Show less

• Introduced and implemented single sourcing and bundling strategy concept.• Review and develop SOR appendices for POA & MP parts APQP, PPAP, measurement equipment and frequency requirements.• Lead and coordinate APQP, PDR DFEMA, PFMEA, Gage Design, Gage R&R and PPAP activities for buy-off.• Participates in program launches cross functional meetings to develop single issues list for driving ownerships and resolutions.• Lead problem-solving activities to support manufacturing… Show more • Introduced and implemented single sourcing and bundling strategy concept.• Review and develop SOR appendices for POA & MP parts APQP, PPAP, measurement equipment and frequency requirements.• Lead and coordinate APQP, PDR DFEMA, PFMEA, Gage Design, Gage R&R and PPAP activities for buy-off.• Participates in program launches cross functional meetings to develop single issues list for driving ownerships and resolutions.• Lead problem-solving activities to support manufacturing locations on supplier related performance issues.• Monitor and perform suppliers’ capability assessments of Run-at-Rates, Process Control Plans, PPM’s, and Warranty Audits.• Establish close relationships with assigned suppliers and actively drive Poke Yoke and Kaizen activities.• Educate suppliers on GM supply power SQMS systems for providing action plans.• Managed Cost Recovery with suppliers based on the SPPS.• Coordinate suppliers change requests through production trial runs for approval. Show less

• Develop and maintain capital investment budgeting worksheets for new launches with global inter-buildability strategies.• Develop the concept of creating VISBOM for communicating and resolving program ‘disconnects’ in targeted Mfg. investments.• Program cost reduction of 30% to define assembly datums in early design reviews for asset reuse.• Member of Program leadership team for approving engineering design changes and modification.

• Lead & solved several complex front-end no-build issues with negligible cost and part changes impact.• Visited supplier sites in US & MX to resolve frames deflection and pre-pierce body mounts misalignment saving overall $110M. • Implement the concept of Buck build in Bodyshop to set closure panels with level II DTS to achieve final fit in General assembly. • Improved Full Size SUV & Truck marriage to frame to meet the competitive quality VTSD resulting cost savings of $40M +… Show more • Lead & solved several complex front-end no-build issues with negligible cost and part changes impact.• Visited supplier sites in US & MX to resolve frames deflection and pre-pierce body mounts misalignment saving overall $110M. • Implement the concept of Buck build in Bodyshop to set closure panels with level II DTS to achieve final fit in General assembly. • Improved Full Size SUV & Truck marriage to frame to meet the competitive quality VTSD resulting cost savings of $40M + $5PC.• Re-designed Fender inner flange holes to increase the adjustments to absorb the frame/powertrain deflections and misalignment.• Designed a Headlamp to Grille Gap control feature by adding a piercing slot enabling trend build.• Re-design End-Gate striker install fixture to reduce refitting to achieve flush interface with box-side outer. • Vision systems template communization’s and additions of critical zoning to correlate the BIW data to the GA builds. • Developed (JES) Sheets to standardize and train both salaried and hourly closure hang and fit teams.• Managed and lead the activities to tune-In dimensionally duplicate Die sets in US and MX.• Resolved Production through-put issues at Oshawa Plant and updated Vision systems to show Man-machine interface time, buffers, MTBF, MTTR, and equipment cycle times resulted efficiency increase from 65% to 90%. Show less

• Ran the production floors in Bodyshop and General Assembly with an achievement of DRR @ 90%.and FTQ @ 85%, • Managed and resolved day-to-day Production Supervisors and Union work force issues. • Provided daily briefing to the Plant leadership staff on Verification stations, throughput DRR, DRL and BPD. • Developed & implemented plans to engage panel fitters measuring their work improved the CARE line quality 95% for shipping.• Lead cross-functional meetings to follow-up day to… Show more • Ran the production floors in Bodyshop and General Assembly with an achievement of DRR @ 90%.and FTQ @ 85%, • Managed and resolved day-to-day Production Supervisors and Union work force issues. • Provided daily briefing to the Plant leadership staff on Verification stations, throughput DRR, DRL and BPD. • Developed & implemented plans to engage panel fitters measuring their work improved the CARE line quality 95% for shipping.• Lead cross-functional meetings to follow-up day to day and repetitive DRR & DRL, GCA issues for permanent resolution.• Created and lead a task force to manage weld flash issues resulted in the savings of $5M across 3 shifts.• Developed templates and vision monitoring for adhesives and sealers reducing the rework with a saving of $1M. Show less

• Managed and lead Issue resolution teams for day-to-day & hardy perennial issues impacting DRR, DRL, Warranty, IPTV & GCA.• Co-Chaired Go-Fast workshops to strategize the production and distribution of SPO parts resulted in the saving of 20M. • Developed vehicle Closure panel fit process layouts, JES, operators training resulted in FTQ of 90%. & $10M savings.• Resolved data disconnects b/w Tier-1 & OEM by developing datum coordination, removed non-value-added work costing $1.5M… Show more • Managed and lead Issue resolution teams for day-to-day & hardy perennial issues impacting DRR, DRL, Warranty, IPTV & GCA.• Co-Chaired Go-Fast workshops to strategize the production and distribution of SPO parts resulted in the saving of 20M. • Developed vehicle Closure panel fit process layouts, JES, operators training resulted in FTQ of 90%. & $10M savings.• Resolved data disconnects b/w Tier-1 & OEM by developing datum coordination, removed non-value-added work costing $1.5M. • Presented lessons learned to Sr. Leadership for documentation as BP and for robust parts designing & manufacturing processes. Show less

• Product design release Door-in-white and its internal components per vehicle design criteria, styling, and packaging requirement.• Worked & resolved with stamping Die lead for meeting formability vs styling, feature & hem radii and class-A surface defects, • Worked with CAE & Crash teams to meet the GM and FMVSS Frontal offset barrier crash, Dynamic Side Impact and Static 214. • Involved in Structural testing, validation of sealing and wind tunnel testing for meeting aero VTS… Show more • Product design release Door-in-white and its internal components per vehicle design criteria, styling, and packaging requirement.• Worked & resolved with stamping Die lead for meeting formability vs styling, feature & hem radii and class-A surface defects, • Worked with CAE & Crash teams to meet the GM and FMVSS Frontal offset barrier crash, Dynamic Side Impact and Static 214. • Involved in Structural testing, validation of sealing and wind tunnel testing for meeting aero VTS requirements.• Prepare BOM list with plan-for- every part for build contents.• Approve production trial runs submitted by supplier quality engineers.• Root Cause and finalize the resolution of TIR’s issued by MPG for achieving Corporate Warranty Goals.• Prepare submissions of EWO’s, PPAP, PTR’s and PADS to authorize plants and/or suppliers for part changes and modifications.• Prepared budgeting of die line-up, vendor tooling, containerization, logistics for submission to program chief for approval.• SOR preparation and releases to program buyer.• Hold part sourcing tech reviews with the buyer for supplier selection. Show less

• Lead industrial engineering activities of developing floor layout for tooling, BEC and material presentation. • Lead the development & finalization of tool design, fabricating, installation, and safety buyoffs with integrated suppliers.• Developed Gantt charts to manage and lead tooling and fixturing Gage R&R studies for dimensional integrity buy-off.• Design door hinges to body fastening system to avoid toe and heel down conditions which results in increased variability.•… Show more • Lead industrial engineering activities of developing floor layout for tooling, BEC and material presentation. • Lead the development & finalization of tool design, fabricating, installation, and safety buyoffs with integrated suppliers.• Developed Gantt charts to manage and lead tooling and fixturing Gage R&R studies for dimensional integrity buy-off.• Design door hinges to body fastening system to avoid toe and heel down conditions which results in increased variability.• Develop pareto & histogram charts to prioritize & root cause of GCA, IPTV, Warranty & JD Power issues. • Managed and lead Bodyshop meetings of a joint cross functional team for resolution of dimensional problems.• Involved in the dynamic & static repeatability studies for calibration and correlation verification of CMM to Vision Systems.• Worked with EDS & NAO manufacturing to develop BIW analyzer software to track six sigma and process mean shifts.• Designed and implemented purple card process to document and track containment moves to avoid certification issues.• Resolved Bodyshop closure hang downtime & throughput issues through PLC Logic reduces MTTR 1.5hr to 10min.• Developed maintenance plans for door hinges hydraulic piercers bolt shearing issue downtime. Show less