PROJECT TITLE: Reducing Cost of Poor Quality due to Quality ComplaintsMETHODOLOGY:•Performed Competitive Benchmarking study of our products w.r.t Performance and Costing•Conducted RCA of recurring Product defects by employing WHY-WHY technique and 7 QC Tools•Proposed, Executed & Monitored Action plan for Process Re-engineering and drafted new SOPs•Designed a 10-Step Quality Check methodology for Performance testing, to mitigate DefectsDELIVERABLES:•Cut down Reprocessing Opportunity loss from 84.8L to 15.2L & achieved Zero buyer Complaints•Achieved cost saving of ₹ 40lac/month by reducing no. of Defective-Sales-Return claims by 30%ROLES AND RESPONSIBILITIES:•Responsible for Quality Assurance/Control of RM, WIP, and FG Inventory•Managed Customer Complaints and exercised Sustainable solutions•Spearheaded team of 7 members to Optimize Cost of Quality through PDCA technique•Identified bottlenecks using TOC & deployed measures to maximize OEE•Automated Data prediction system to reduce Human errors & ensured POKA YOKE•Formulated Manufacturing Control Plans & Failure Modes and Effects Analysis•Accountable for Legal Requirements concerning Audits like ISO 9001 & OekotexACHIEVEMENTS:•Raised RFT of the Department from 97.3% to 99.8% by employing “14 Principles of TPS”•Reduced Turn Around Time by 33.3% by Standardizing the operations comprising HMI•Awarded as the “ENVIRONMENT-HEALTH-SAFETY CHAMPION” for the year 2018-2019