Dev R. Email & Phone Number

Bhopal, Mp, In

India

Quality and Reliability Division Head

India

• Responsible for Total Quality Management of Machined Export Oriented Vehicle Assembly Components for BMW Germany.• Responsible for Quality of Ford Axle Housing Assembly-New Launches.- Ford USA. • Implemented "Lean Manufacturing" Concepts . to "Ramp up Quality Output" to meet Customer "Ask-Rate" of 300 Ford Housings from existing 220 Housings, by Reducing Inspection time Considerably . (Equivalent parameters eliminated on Equator(Mini-CMM) added on Position Receiver Gauges ,with Stricter -80%, Guard Bands.) • Reviewed and Implemented Better Changed Manufacturing Process, Gauging strengthened on Station to ensure "Built in Quality Right from Processing".• P&L Assessment for Cost at Quality- Department Level and Initiatives to bring down Department Variable Cost, Warranty Expenditure, Consumables, and Cost of Poor Quality Reduction to within 0.5% turnover. • Responsible for Budgeting of Finance at Quality Department Level ,based Considering Last year’s Estimate and New Project Projections and New Businesses at hand.• Developed as CFT-Leader , of New Product Development Team, in the development of Ford Aluminium Axle Housings by modification of existing Cast Iron Housings of Ford-USA with Design Change and carry over to Aluminium.

Pune, Maharashtra, India

• Responsible for Bogie Equipment -Section Quality: Manufacturing of Brake Callipers of Metro and LHB coaches . • Metro Coach: (1) Compact Callipers (2) Tread Brake unit• Railway LHB Coaches:(1) Conventional Calliper •Resolved Field Complaint of Compact Calliper jamming in Field during Assembly at Customer end , by restudying Tolerance Stack up in journal of Housing of Slack Adjuster Assembly and Design Modification. • Responsible for Brake Control- Section Quality: Brake Control Hybrid Valves, Stop Cocks and Distributor Valve Accessories, Pantograph Actuation Valves. • Distributor Valve Machining with Area specific Leak Testing. • Worked in New Product Development of Alstom CCB Hybrid Assembly( Electronic CCB Version) • Resolved Successfully In-Process Quality issues of(a) Dead Stroke Setting of Levelling Valve by Process Correction at Supplier end. • Responsible for Quality of Damper Assembly Section • (1) Yaw Damper (2) Primary Damper (3) Secondary Damper . • Special Focus on Performance Testing of Dampers at Defined Force Versus Specific Velocity. Graph Analysis of Tension and Compression at designated speed. Force Vs Displacement and Displacement Vs Time ,graph of last 11 cycles. •Handled Quality of Railway Air Compressor Assembly for maintaining pressure in Brake Pipe for Loco. Machining of Duplex Valve with Final Assembly with Radiator.Air Compressor Assembly for Train 18 and Train 20. •Incharge Quality of Surface Treatment Shop with Processes of: 1) Anodizing (2) Manganese Phosphating (3) Zinc Phosphating (4) Spray Painting (5) Waxing. •Quality Incharge of Over Head Equipment Assembly (OHE) -HVAC of Metro..

Pantnagar And Pune

• In charge Machine Shop Quality of 1.4l, Superace,800CC Dicor Machining and Assembly Lines.• Developed Machining of 800CC Aluminium Block+Bed Plate -A New Model Block with Cast Iron Liners making Cylindricity of Bores within 4 mic. achievable• Implemented Cylinder head material change (to address head crack cases in field) at Foundry Stage at par with material of competitor Models and like Platforms.• Quality Incharge of Welding and fabrication Shop- of Chassis of Small Commercial Vehicle. Welding at Proper Voltage and Wire Speed with Regular Audit Compliance of the same. •CFT Lead of Automobile Chassis Modification :Took Lead role with Design Team to eliminate, Excessive welding Cross Members by Bolted Joints to build strength to the structure and reduce failure rate of Chassis in Field.•Successfully Implemented New Development and Productionization of Future Engine of 800cc Dicor Engine Assembly and Machining - Future Engine of LCV Segment. •Led the Launch of Ace Mega Model and Ace Mint vehicle with 1.4l Dicor Engine.•Successfully Developed New Suppliers for Crank Shaft-M/s Mahabal & M/S Amul for Fractured Con.Rod Development.• Implemented Mapping of Suppliers in 3x3 matrix of part criticality Versus supplier capability based on supplier rejection/ rework data in rolling last six months average , assigning weightage for Field Failures.• Responsible for Monthly monitoring of DOL and NON- DOL items. Improvement activities at Non- DOL Suppliers and bring them to DOL Category as per laid criteria.• Involved in increasing direct pass of engines from 80% to 98% and maintaining gear box DMP score at over 98.7% D.M.P. by improving in process setting and having it a more automated Kaizen approach.• Led Implementation of "WORLD CLASS QUALITY-WCQ" - "Built in Quality", " Continuous Improvement" , and " "Standardization" Pillars, to Slowly Mature the Process and Migration, to "Defect Prevention", finally undoing with Quality Gates.

• In charge Machine Shop Quality of 1.4l, Superace,800CC Dicor Machining and Assembly Lines.• Played Pivotal Role in Implementation of "DO IT FIRST TIME RIGHT "- approach for Engine shop. To achieve this was instrumental in making Most Upstream Processess tighter than downstream processes.• Champion of TPM Quality Pillar and Equal involvement and participation in other pillars of J.H., @ Autonomous Maintenance. •Champion of SMED- Single minute exchange of Dies .Was Team Leader in minimising External and Internal Set up Times to boost Productivity with Quality• Managed warranty claim analysis, Customer Care quality and implementing actions for bringing down 3MMA,6MMA, 12MMA,18MMA -IPTV-(Incident per thousand Vehicle )and EPV-(Expense Per thousand Vehicle) of top warranty complaint parts in low kilometre failures and Elevated Kilometers, by Design modification and Process change.• Proven skills in managing warranty claim analysis, customer quality and implementing actions for bringing down IPTV and EPV of top warranty complaint parts in low kilometre failures by Design modification/ Process change,inProduct/Aggregate,design and strengthening Process making it more robust and leak proof• Dedicated Mentor and Excellent Quality Trainer for Statistica lQuality Tools, SPC, MSA, Six Sigma Techniques, TPM• Tuned as a Team CFT Member , with Design Team Onboard- Engine performance characteristics as per Design pass off norms with rationalisation of testing cycle time as a Practical Production Solution at Plant level, but agreeing to all Major parameters at Design Testing Level at the Said Altitude and Pressure and Conditioned Environment.• Improving engine-testing characteristics –Power, Fuel delivery and smoke, within ±5%, between bed to bed readings, and within Bed Variation ±2%. Initiated Special drive to eliminate Bed-to-Bed variation to minimum, driving it to and below 5%, by analysing and eliminating all Assignable causes.

Hosur And Pantnagar

• Responsible for Assembly and Quality of Ashok Leyland -Hino Series- HCV Engine with Testing. • Successful as CFT in Implementing Machining of Platform B-Block in the same set up of Platform -A Block without Additional Investment.• Incharge Quality Machining of all 5C at Supplier end and inhouse.•Succesfully Validated Machining of Hino Semi Finish -Block and Head at In-house Facility, eliminated Offloading as Huge Cost Reduction Project.• Developed In-house Machining of Crank Shaft on Heller Machine with Machining of Cam Shaft and Split Connecting Rod in New Set up.• Incharge Machining of All Speed Gears with Bore Grinding Operation for noiseless Operation.• Managed New Development of Platform- B- CRDI Diesel Engine ,with H P Pump , from traditional Platform A type with FIP.•Managed New Development of Neptune Series Heavy Duty Engine with Engine Blocks of 120 Dia. Bore.• Responsible for Monthly monitoring of DOL and NON- DOL items. Improvement at Non- DOL Suppliers and bring them to DOL Category as per laid criteria

Greater Delhi Area

• Overall Incharge -Manufacturing and Quality of Machine Shop and Assembly (Gear and Sprocket Line, Final Grinding line) and ensuring Final quality of Engine and Gear Box . • Responsible for Output Monitoring Per Line on an Hourly Basis. Andon Analysis of Lost Hours of Production with CAPA -corrective Action for top 5 Contributors on a monthly basis • Responsible for Bringing down Department Variable Cost like Warranty Expenditure and Reduction in Consumable. Reduction in Cost of Poor Quality to within 0.5% turnover. •Played Crucial Role as CFT Member in Manufacture of EV-Electric Vehicle , with Imported Batteries. A First Initiative by Any Automobile OEM of India •Successfully Implemented CELLULAR MANUFACTURING (Using Nagare Graph Sheets) and TPM on shop floor for New Cells Created Integrally dedicated to Independent Components.• Successfully Implemented Concept of SINGLE MINUTE EXCHANGE OF DIES - bringing down Considerably Setting Time and Heavily Reducing Availability Loss Boosting OEE of Shop.• Champion of SPC, MSA , Single Minute Exchange of Dies and Lean Manufacturing. •Implementation of Cubic Boron Nitride Honing Sticks Replacing Fibre Sticks - as a Major Cost Reduction Project.

Greater Delhi Area

• Incharge Manufacturing of Gear Shop having Broaching, Gear Shaping, Hobbing and Gear Shaving Facilities , Differential Housing Machining Shop. After heat treatment gear bore grinding and Surface grinding operations with tooth grinding of gears.Lapping of Crown and pinion of Differential Gears, Tooth grinding of Speed gears. • Incharge - Axle Shaft Machining , Induction Hardening, Heat Treatment with Differential Housing Assembly• Responsible for Maintaining of proper Tongue profile in Crown Wheel and Pinion at Final Quality check of heel, tip, toe, length and width of crown and pinion -100% before final passing to Assembly in Sets• Incharge Grinding Section Comprising -External and Internal grinding (Both Center less and Between Centre grinding) of inside bearing bushes.