Quality Six Sigma

Mukesh Agarwal E-mail:

**********@*******.***

**** ******** ***** *****, *****: 443-***-****

Baltimore, MD 21128

Education

. BS - Electrical Engineering

. MBA (Purchasing major)

. Six Sigma Master Black Belt

. Certified quality auditor

Major Achievement:

. Managed multiple locations with best practices, motivated staff,

result oriented and continuous growth.

. Saving of total $3.7B from all Lean, six sigma projects (product,

process, suppliers)

. Expertise in operational excellence, supplier development, stake

holder management, driving results/efficiency, supply chain,

continuous improvement, data driven approach, zero defect approach,

improve capabilities, leading cross functional teams, customer

satisfaction and revenue growth.

. Global reliability, compliance and regulation management.

. Effective global change management and project management.

. Risk, financial analysis, decision matrix and global integration with

zero defect methodology.

Professional Summary

. Over 29 years of result oriented experience in the field of

Operations, Quality, Supplier Quality, Purchasing, Manufacturing,

Process and Project Management with broad strategic thinker, clear

vision, direction of world class change management and continuous

improvement.

. Provide leadership to the strategic planning process and implement new

programs strategic initiatives, optimization and bench marking.

. Generate, manage and monitor key profitability and productivity

measures to assess project and company performance. Quality, cost and

delivery matrix to meet customers requirement.

. Serve as the critical liaison between Customer, Client Services, Field

Operations, different functions and global Team Members including

suppliers/partners.

. Excellent customer (internal + external) interface capabilities,

Strong organizational leadership, Strategic planning, Feasibility

studies, customer specification sign off and project gate review.

. Extensive experience in implement world class systems, processes, Six

Sigma methodology. Cost reduction approach, value analysis with strong

focus on preventive measures & ROI.

. Coaching, mentoring, facilitating & leading cross-functional teams for

projects and through various phases of Lean, Six Sigma, DMAIC, DFSS,

operational excellence ( Certified trainer for Lean and Six Sigma.

. Extensive experience in implementing/managing quality systems ISO9001,

TS16949, AS9100, FDA, ISO17025 + Environment health & safety ISO14001,

18001, Nuclear, Defense standards, compliance and regulatory standard.

. Expertise on Reliability, Testing (DVT), Repeatability, DOE, warranty

reduction and appropriate risk analysis, CAPA.

. Supplier management ( Developed and managing supplier in 29 different

countries, 22 million components each year from 12 years with zero

defect methodology and achieved less than 100 PPM globally.

. Established the supplier development and supplier quality function in

different organizations, Supplier selection and approval process,

audits, suppliers training on Lean/six sigma to reduce cost,

corrective action, supplier performance/score charts, Improve

Capabilities, Quality/Cost/Delivery improvement plan.

. Customer complaint (internal/external) timely response, Improve

customer satisfaction. Reduce warranty, rework and scrap costs.

. Purchasing cost breakdown, reduce purchased component cost, improve

quality & delivery.

. Identify stakeholders, their needs and action plan..

Professional Experience:

Smiths Detection, Edgewood MD ($6Billion Smiths group)

Global Quality and supplier quality Director (Dec 2011 - Current)

(Manufacturer of bio, chemical, bomb, radiation, drug, trace, weapon

detection systems for military, airports, homeland security, border

protection, seaport scanning security and commercial businesses)

. Develop and implement global standards, processes to eliminate the

variation.

. Data driven approach to analyze and strategic planning for reduction

of overall cost with new product/program, warranty, rework, scrap,

services, supply parts and value engineering.

. Improve profit of margin on all existing or new product

implementation.

. Develop and manage suppliers globally for zero defects.

. Conform to all global systems, regulations, standards and compliance.

. Coach and implement Lean, six sigma culture, Value stream mapping,

systematic problem solving, lesson learned and risk identification.

. Continuously strive for global operational excellence by developing

error proof systems, products, processes.

. Develop and implement best practices, quality culture, Improve profit

margin, customer satisfaction/services, optimization and bench

marking.

. Drive the quality culture of preventive measure, process oriented,

continuous improvement and customer voice top priority.

GE Energy, Corporate Office, Atlanta ($47 Billion Energy Division)

Corporate Global Continuous Improvement BB (Feb 2010 - Dec 2011)

. High level black belt projects to reduce the cost, cycle time, touch

time and improve On-Time delivery, New projects cycle time reduction

including software & firmware development.

. Operational Excellence, Kaizen, agile and facilitate as scrum master

. Train the team on FMEA, calculate business risk and make improvement

plan of success. Compliance of product/process and systems.

. Coach globally for Green/black Belt and mentor their cost

reduction/continuous improvement projects.

. Coordinate different cross functional teams world-wide to get the

data, analyze and improve through DMAIC. Support and integrate the new

acquisitions

. Provide leadership to the strategic planning process and implement new

programmatic strategic initiatives

. Generate, manage and monitor key profitability and productivity

measures to assess project performance;

Achievement: Saved 19000 TT hours, 87000 Cycle time hours, Reduce New

product implementation cycle by 5 months, saving of $290M.

Faurecia Automotive System, Greenville, SC (A $15.0 Billion "Faurecia

Automotive INC".)

Director Quality & Supplier Quality ? Also acting plant manager (Sep 08 to

Jan 2010)

Manufacture the interior modules such as complete door panels, Instrument

panel, Center console, seats. (Just in time facility in line with BMW).

Major Achievements: ( Operational excellence

A) Customer PPM reduction from 770 to single digit.

C) Numerous daily complaints reduced by 80%, Customer debits reduced by

68%, warranty cost reduced by 81%, Timely response to customers.

D) Customer satisfaction increased, resulted in new business (No more

new business on hold due to poor quality).

E) Cost saving by $2.7 Million with small projects, process

improvement, scrap reduction and by improving supply component

quality/vendor management.

F) Achieved ISO9001, TS16949 & VDA6.3 in six months after joining.

G) Reduction of supplier incidents, supplier PPM reduction from 940 to

29 PPM.

. Achieved by improving teamwork, built some new team, coaching,

motivation, set clear objectives/targets, planning and timely

follow up.

. Implemented all the quality tools, Zero defect methodology, six

sigma approach, understand customer expectations, implement

standard/boundary conditions/samples, improve control plans,

standard procedures, layouts, implement poke yoke, audits,

immediate reaction plan, SPC, supplier management.

. Review customer voice; make action plan, coordinate with multi

functions.

. Supplier's weekly/monthly escalation meeting, Timely PPAP and

improve supplier capabilities for quality/cost/delivery. Strong

focus on preventive measure & continuous improvement.

. Provide leadership to the strategic planning process and implement

for new programs initiatives to have quality at first time, lower

cost and cycle time.

. Generate, manage and monitor key profitability and productivity

measures to assess project, products, supply parts performance.

Valeo Automotive Inc., Greensburg, IN (A division of $13.2 Billion "Valeo

Automotive, INC.)

Supplier Quality Manager (North America) (Also Six Sigma Manager (North

America) ? (April 2000 - Sep 2008)

Manufacturer of cooling modules (Radiator, condensers, turbo charger, tri

cooler, Charge air cooler, heater core, Motor fan assembly, hydraulic fan

assembly etc) for all the major car manufacturers: Chrysler, MB, Ford, GM,

BMW & Honda

Major Achievements:

Saving of $600M worldwide by improvement projects including supplier

development.

Developed the suppliers in 19 different countries such as China, India,

Taiwan, Turkey, Poland, South America, Malaysia, ---

. Coach/train the team for Zero defect, Six Sigma, Select and monitor

the DMAIC projects for scrap reduction projects, efficiency

improvement, and cost reduction.

. Developed & managed the current and new vendors with zero defect

methodology, established a global supplier quality department,

processes, training, score cards, worst supplier monthly meetings for

improvement plan.

. Train and develop the team for PDCA/QRQC (quick response quality

control), root cause analysis, Lean manufacturing and process mapping

and value stream analysis.

. Ensure and review the new programs road map also check that all the

previous lesson learned are included in the new product

development/new programs control plan, poke yoke, measurement methods,

PFMEA & timely supplier components capabilities, audit and part

approval (PPAP) etc.

. Responsible for quality of 127 global suppliers in 19 countries, 1900

active components, 25.4 million components every month also support

the sub suppliers quality and capabilities with less than 20 PPM

defects per month.

. Developed & managed suppliers in low cost countries since 1992 with

zero defect methodology, coach and mentor the suppliers to improve

capabilities, implement more error proofing, Six Sigma approach, Lean

manufacturing approach & preventive measures.

. Responsible for quality management systems ISO9001, 14001, 18001 and

TS16949.

Boeing Commercial Airplane Group, Boeing Fields, Seattle, WA

Sr. Engineer - Flight test quality & reliability (MAR 98 - Jan 2000)

Major Achievements:

Saving of $2.6B by reducing the test cycle time.

. Managed the completion of flight test and FAA approval of new

generation 737 and 777 aircrafts on time.

. Advanced reliability testing of all system configuration and

integration at flight deck, check the proper functioning of

components, supply parts workmanship standards and value engineering.

Manage vendors for quality, audits, corrective action,

compliance/standard/regulations and absolute zero defect.

. Collect the flight test data, analyze and present for improvement.

Verify functional Test Simulation per FAA. Responsible for AS9100

quality systems.

. Arrange reliability-tested components for Refurbishment of Aircraft

(after testing) in all zones (Interior, Exterior), Flight Control

systems, Flight deck, Cargo area and Safety systems.

PepsiCo Holdings Ltd. (Western India)

GM Projects ? Plant Manager Operations (Jun 96 - Jan 98)

Major Achievements:

. Provide leadership to the strategic planning and execution of new

green filed projects. Achieve within budget, on time, excellent

quality, zero accident and world class process/systems.

. Generate, manage and monitor key profitability and productivity

measures to assess project and company performance;

. Recruit and build complete new team, training, apply world-class

systems, Zero defect approach, motivate the team and safe environment.

FDA and other government approval.

. Exceed the first year manufacturing/sales goals by 17%.

. Vendor/Supplier Selection and Develop in accordance with quality

systems/standards in south East Asia.

Ford Climate Systems (India)

Quality & supplier quality manager (Aug 92 - Jun 96)

Manufacturer of engine cooling modules:

Major Achievements:

. Project head for the new green field project and completed well in

time, with in budget, regulatory approval, selection of new suppliers,

recruit new team, training and implemented world-class systems,

achieved in one year ISO9002, Ford Q1, Ford TPM.

. Develop customer requirement and standard. Exceed sales figures as

planned since project completed before time.

. Quality, testing, reliability and repeatability analysis for product

and supply components. Develop and Achieve Annual Operating Targets,

Objectives for Continuous Improvement.

. Develop and established new supplier development and supplier quality

department, procedures, training, check sheet, coaching and preventive

approach.

. Manage changes with system, part, drawing, process and suppliers.

Mitsubishi Electronics - A joint venture of Samtel & Mitsubishi (India)

Sr. Engineer/Assistant Manager - Manufacturing and Process improvement (Apr

88 - July 92)

(Manufacturer of electronic equipment for automotive and aerospace)

Training completed in Japan for six months on Toyota production system,

quality circles and Kaizen.

Major Achievements:

A) Learned and implemented Japanese quality systems, process improvement

and six sigma methodology.

. Design of experiment, gauge study, testing, FMEA, data analysis and

coordination.

. Implemented quality Japanese Concepts as TQE, Quality Circles, Quality

Improvement projects (QIP), JIT, SPC, and Kaizen Effect for continuous

improvement.

. Making Procedures and Implement ISO-9001. Audit, Review & Maintain

Records.

. Develop and Implement quality systems to work on Zero Rejection, Zero

waste, Zero Accident, Zero Break down and Lean Manufacturing.

. Interim and Permanent Corrective action activity plan in process and

with customer/suppliers.

. Selection of suppliers, specification, quality inspection plan,

supplier feed back and corrective action, PPAP's.

. Six Sigma training completed in Japan, Implement the methodology and

involved in three DMAIC projects.

Oriental Carbon & Chemicals (joint venture of Philips Carbon, USA) - India

Engineer Manufacturing (Aug 83 - Mar 88)

(Manufacturer of raw material for all automotive and aircraft tires and

rubber products)

Major Achievement: Develop the mindset for Aerospace quality systems.

. Responsible for production and process control. Quality and Testing,

scrap reduction, Analysis & corrective action.

Member:

American Society of Quality

Automotive Engineers association

American manufacturing engineers association

American Compliance and Regulation Board

Technology Association of Georgia

Lean Enterprise Institute

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