Dev R. Email & Phone Number

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.
• 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.

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.

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.

• 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.
• 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.

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.

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.

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.
• 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.