Worked with problem suppliers to eliminate quality issues in achieving the goal of reducing PPM and improving OTD. Achieved by closely working with Engineering, Supplier, Purchasing. Resolved long standing failure issues at suppliers using six sigma methodology like FMEA & 5 WhyLead Process Improvement Initiatives for “In House” Production and with supplier base. Utilizing problem solving techniques including Six Sigma / DMAIC. Helped to achieve an overall 50% reduction in PPM & Customer complaintsLead cross functional team (Supplier, Engineering, Purchasing, Quality & Manufacturing) to resolve key product/Process issues & helped to exceed the desired resultsPerform Quality System/Special Process Audits at the supplier per ISO/FDA as part of compliance requirement (casting, coating, welding, Assembly)Help to reduce scrap & rework in house and suppliers resulting in hand savingsLead & facilitate system improvement process On Site events to improve the quality and OTD for suppliers & addressed customer issues.Developed & implemented the criteria for supplier inspection for supplier base which reduced the supplier source inspection & streamlined the supplier processes to enhance the quality of the received parts.Enhanced supplier performance & implemented supplier quality improvement strategies through working in a cross functional team with Engineering, Manufacturing, Quality, Purchasing. Utilized advanced problem solving tools such as Six Sigma, FMEA, 5 Why, 8DsImprove Supplier Lead Time by providing on site value stream mapping.Lead Material Review Board (MRB) for nonconforming parts to ensure timely resolution and assure the smooth operation of the CAPA and SCAR systemPerform internal audits of processes, facilities and coordinate External/Customer Audits Review/approve suppliers 1st Article/PPAP, submit 1st Article/PPAP to customers

Led& facilitated kaizen events as part of JBI lean initiatives. Improved product flow & reduced parts machining operational time reduction of more than 30%Led Kaizen event to reduce lead time of machining parts by using drop off material resulting savings $7000/month.Reduced 35% of appraisal cost of inspection process. Accomplished by identifying Parts CTQs, Improving Inspection Techniques, Parts Inspection Setups.Reduced packaging cost of machine parts by using reusable totes. Improved efficiency, parts counting, handling time, staking, waste & ease of shipping

Developed & Implemented Supplier Development Strategy & took actions to improve supplier qualityEstablished audit procedures appropriate to the suppliers to ensure adherence to quality standardsProvided Lean Manufacturing Training & introduced the Principles in the supply baseCreated and implemented Supplier Scorecard ProcessCreated Supplier Risk Assessment & mitigation Process to reduce production interruptionsEvaluated supplier readiness and adherence to requirements at all development and qualification stagesDeveloped, analyzed and reported statistical data to determine the level of level supplier quality and took appropriate improvement actions

Led continuous improvement projects throughout facility and improved the processes by applying DMAIC, Lean & Six Sigma tools: Value Stream Mapping, GR&R, SPC, Control Plans, Kaizen, 5S, Statistical Analysis, 8D, 5Why’s, FMEA, Cause & Effect Diagram, Pareto Analysis etc.Developed & implement Continuous Improvement Processes Methods / Techniques. Provided training to Managers, Engineers, Supervisors, OperatorsDeveloped APQP Process and provided Training to Engineers/Managers. Launched the Process on Trailer Hitch Project.Developed Project Management System in the company taking consideration of Product Development Process. Launched it on Sharp Terminator Project.Monitored Key Performance Indicators (KPIs), and communicated to Senior Management Performed data analysis and generated take actions to improve processesConduct Management Reviews to review QMS for its suitability /effectiveness and identify the need for changes and opportunities for improvement.Performed internal audits of processes, facilities and documentation to assure compliance with internal procedures and ISO/FDA regulations and requirements

Developed Quality Management System (QMS) and certified company to ISO 9001 certificationDeveloped Training Program (ISO Standard Requirements, Internal Audit, GD&T, Measuring Tools/gages, Parts Acceptance/Rejection criteria)Developed Customer Feedback Process, Customer Complaints, RMAs & took corrective actions to enhance customer satisfaction & problem resolutionDeveloped and initiated methods for inspection, testing, and evaluation Developed and provided training to engineers, QA Inspectors engaged in measuring and testing parts and tabulating data concerning materials, products. Created work instructions, launched GR&R process, Job processing, document control Developed and implemented 1st Article/PPAP processesManaged CAPA & compliance audit corrective actions.Developed and implemented process for inspection equipment, gages, and tools maintenance and calibration Developed Key Performance Indicators (KPIs), monitored and communicated to Senior Management Performed data analysis and generated take actions to improve processesDirected and performed inspections of receiving, in-process, finished goodsLed and facilitated the activities of the Non-Conforming Material Review Board (MRB) to ensure timely resolution and appropriate documentation.Managed Engineering Change Control (ECN) process.Wrote and implemented procedures and specifications detailing every aspect of an effective quality system that complies with ISO and other applicable regulations and requirementsResponsible to ensure to follow all applicable Standard Operation Procedures (SOPs) and regulations including FDA 21 CFR 820, ISO13485 & ISO 9001 requirements, by implementing an effective and efficient QMS

Supervised inspections of 1st articles, in process, receiving and final Inspection Responsible to process all NCRs, resolution of NCRs including follow up NCR dispositionManaged Inspection Tools, Calibration, Testing & mentoring workers on inspection/testing/calibration methodsDeveloped and implemented test methods and standards for the testing and evaluation Performed process monitoring and improvement tasks using SPC techniques.Improved process/product quality by performing teardown analysis on customer returns/ nonconformance parts Developed new Control Plans(CP), and coordinated with manufacture to make sure critical characteristics are captured in CP, Work Instructions & PFEMA,Led problem solving teams to find the root cause, corrective action implementation/validation by using 8D/5Why techniquesLed Continuous improvement actions by, Kaizen, Kanban, Value Stream mapping.Worked with R&D with launch of new products, planning of new gages, testing methods preproduction CP, resolution of quality issues.Conducted internal ISO 9000 compliance audits to ensure the plant ISO 9000 program is followed and standards are being maintained.

Performed New & existing supplier audits to be in compliance with TS 16949, monitor timely closures of findingsWorked on Design for Manufacturability issues and integrated manufacturing suppliers with Engineering teams to resolve these issues.Worked through all elements of APQP for In-house processes and also coordinated with suppliers to develop APQP activities. Participated in Technical Reviews, Run@Rate Processes, etc.Reviewed PPAP’s and followed up with PDCA approach to resolve Supplier issues.Determined and confirmed root cause of quality problems and validate effective and timely resolutionsImproved quality performance of suppliers by conducting workshops at the supplier location, and providing technical assistance and support as requiredCarried out capability studies on pilot runs and MSA on all gauges and measuring tools as a part of process design of APQP.Coordinated with the production team to develop process changes by updating process flow charts, PFMEA’s & Control plans.Performed process monitoring and improvement tasks using SPC techniques.

Developed Test Plans for Full Vehicle/ System/ Subsystem levelsCoordinated Lab/PG, including FMVSS Testing via planning, tracking, executing and concerns reporting as well as problem resolution. Coordinated with Testing Group for component validation and CAE group for FE analysis; interpret results and co-ordinate design changes to the model, if requiredPerformed studies on failure of parts during testing, Root Cause Analysis (8D) & generated test results reportsParticipated in cross-functional problem solving teamsDeveloped Test Procedures to verify product for Vehicle Attributes (NVH, Durability, Safety & Performance). Supported Vehicle Programs by designing and implementing custom made tests to assure compliance to the changing industry requirements. Developed integrated CAE and Testing Methods to verify System Design Requirements by using CAE software such as IDEAS, MSC NASTRAN, HYPERMESH

Generate Design concepts and Evaluate packaging studiesMaintain Engineering documentation of design progress (DFMEA, DVP&R) and Engineering BOM from concept to Production. Design Review minutes, regular Program reviews and Open issuesCoordinate with Testing Group for component validation and CAE group for FE analysis; interpret results and co-ordinate design changes to the model, if requiredRefinement of product design after evaluations of rapid prototype models and Tool tryouts, maintain and resolve design, manufacturing, assembly issuesUnderstanding the failure of parts during Testing; Evaluating Root cause analysis for design changes & generate technical reports