• Managed the APQP team to drive and meet customer timing and expectations including activities for prototypes, sample builds, and mass production ramp-up of e-transmission components.• Developed and maintained a detailed project plan, including schedules, budgets, and resource allocation.• Reviewed and assisted with the development of line layouts, process flow, capacity analysis, and equipment preparation with manufacturing engineering.• Assisted with supplier process & quality development and evaluated their quality performance based on customer’s and company’s requirements.• Led project kick-off, design review, pre-production, part review meetings & customer audits and ensured that all actions and decisions are captured and communicated to stakeholders.• Led and monitored the progress of machine shop modification, relocation of machines and start of production at new manufacturing unit as part of 4M change management.• Collaborated with the packaging specialist to ensure product packaging design meets requirement and packaging is available to support various development phases.• Monitored project progress and provided regular status updates to senior management and other stakeholders. • Identified and managed project risks, issues, and dependencies & escalated any critical risks when necessary.• Collaborated with APQP team to develop PFMEA, Control Plans, Part Inspection Standard and followed-up on improvement actions.• Provided customer documentation as required (surveys, capacity, schedules, project status) & built relationships with key customer contacts, monitoring their satisfaction regarding company performance

• Designed & implemented visual management status boards in machine shop improving efficiency.• Identified Muda in process & suggested improvements with a potential of 10% increase in machine utilization.• Audited process manufacturing process control plans, identifying and addressing process gaps to enhance overall product quality and customer satisfaction.• Led business process re-engineering of an off-highway product to improve output and reduce cost.• Mapped As-Is status and prepared To-Be process map after identifying improvement opportunities. • Prepared and communicated product’s technical requirements to vendors (forging, heat treatment, welding & painting) for RFQ and evaluated their proposal for conformance with requirements. • Planned and coordinated with internal resources & vendors achieving timely development of prototype.• Prepared and presented key project information to customer & management for ease of decision making.

•Collected & analyzed quality performance data, identifying & implementing continuous improvement ideas leading to 20% savings in scrap cost.•Provided support to quality processes (non-conformances, change management) of North American manufacturing sites.•Led development of quality control documentation to effectively manage risk and meet customer satisfaction.

•Monitored setup of QC lab - developed & implemented QMS in accordance with IATF 16949 requirements achieving passing of audit without any nonconformance.•Actively participated in internal, external, customer and layered process audits to ensure compliance. •Hired and coached technicians to conduct all laboratory work in accordance with established test procedures based on ASTM, JIS & company & customer’s standards. •Maintained accurate & dependable gauge calibration & inspection records for over 300 measurement gauges & conducted MSA studies to ensure acceptable measurement variation.•Collaborated with teams to perform cross functional machining, electroplating & assembly line audits & trials, initial process capability studies, product validation & APQP requirements for successful launch of 4 new vehicle model brake assemblies.•Analyzed process data & provided recommendations for process improvements leading to cost savings of more than USD $ 5K.•Assisted in preparation of PPAP documentation – Process Flow Chart, PFMEA, Control Plan, Inspection Sheet, Statistical Process Control (SPC) Charts, Standardized Work Instructions, Checking Aids etc.•Interpreted engineering standards & blueprints & prepared receiving inspection plans for more than 20-part numbers.•Actively supported Corporate Supplier Quality in auditing ductile iron casting & stamping suppliers in Mexico for localization & identified opportunities for cost reduction.•Reviewed and approved interim and final PPAP submissions of suppliers. •Set performance improvement goals for ductile iron casting suppliers & achieved PPM reduction from over 7000 to less than 1000 (improvement by 85%). •Verified effective implementation of corrective & preventive action (CAPA) at supplier facility using different QC problem solving tools and their closure in timely manner. •Conducted investigation & assisted in report preparation (8Ds, Ishikawa, Is-Is Not, 5 Whys) of customer’s quality & warranty concerns.

•Performed engineering responsibilities like various materials-related analyses like corrosion testing, adhesion testing, microstructural study, fracture analysis for brake components.•Improved metallurgical sample turnaround time by 50% (from 15 mins to 10 mins) by developing sample preparation method for heat treated rotors. •Studied customer’s process patent who demanded royalty for a product manufactured by company, successfully countering the claim & resulting in over USD $ 100K savings for the company.•Led materials testing for a corporate manufacturing location restructuring project, communicated results with customer using experimental design principles (DOE) & obtained approval resulting in production capacity increase by 20% at one unit & new business worth USD $1.5M at the other.•Reviewed & checked engineering drawings for material-related items.•Supported production-phase projects such as production fractures, warranty concerns, process change requests, cost reduction activities, materials analyses & research as required.•Researched & conducted benchmarking studies to facilitate development & release of global engineering specifications related to material properties.•Attended CFT meetings & coordinated with other functions such as Design Engineering, Product Testing & Purchasing to help develop an open issue matrix & closure of action items via material related solutions.

• Learnt operation of Thin Slab Caster to produce slabs for hot rolled coils of various steel grades.