Quality Six Sigma

Umesh N. Rao

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SUMMARY

Global Quality (QRE/QA/QC/QS) Leader who functions as a strategic business

partner by linking Global Quality, technical and regulatory activities in

support of the organization's global business objectives. Successful

record of accomplishments in leveraging business and financial acumen to

develop Quality driven business solutions. Adept at creating traditional

and nontraditional metrics which promote customer contact behaviors,

ensuring highest levels of customer satisfaction, long-term customer

relationships, supplier/outsourcing quality developments, market

penetration, preferred supplier status to improve business quality

excellence.

. Established quality vision, mission & quality policies

. Strategic Quality Planning

. Six Sigma Black Belt

. Lean Manufacturing

. Electronics, Electro-mechanicals, Assembly, Fabrications, Welding,

Metals, Automotive, Aerospace, Chemicals, Plastics etc.

. PSDMS, 8Ds, 5Whys, COQ, RCA etc.

. Product and Process Improvements

. ISO9001, APIQ1, ISO/TS29001, ISO/TS16949, AS9100, ISO13485,

ISO14001,OHSAS 18001, SA8000, ISO17025 etc. Certifications

. TQM, TPS, TOC, TPM, VSM, VA, VE, CIs, Kaizens, DMAIC, DFSS etc.

. Quality Trainings & Tools.

. Global Dashboard Metrics, BSCs, Gemba Charts etc.

. Supplier/Outsourcing Quality Management

. QA/QC & Reliability Engineering

. System/Process/Product Audits

. APQP, PPAP, FMEA, SPC, MSA, DVP&R, DOE, QFD, GR&R, GD&T, CAPA, CARs/PARs,

etc.

. Shainin & Shingo techniques

. IPC-610, J-STds. Etc.

. EASA, FAA, 14CFRs (Parts 21, 45 etc.), API Q1, NBIC, ASME codes, ASTM

test methods, AWS Codes, etc.

. Internal audits, management reviews, document & data control, process,

product and systems audits, regulatory audits, supplier and customer

audits.

. Company wide CIs, Change Initiatives and "Hands-On" Leadership style

SELECTED ACCOMPLISHMENTS

. Led effort to incorporate global quality system, which resulted in:

- Reduction and re-assignment of manpower with over $950K in annual

savings.

- Consolidation of quality information from multiple businesses

across multiple international regions providing senior management

more timely access to Quality Systems information.

- Timely dissemination of quality information throughout all levels

of global businesses leading to higher productivity and increased

communications.

- Implemented global "Strategic Enterprise Certification" for

ISO9001, ISO/TS16949, ISO14001, ISO17025 and EN45001 etc.

certifications, with a 70% registration and audit cost reduction.

. Initiated and implemented "Customer Care" and "Customer Partnership"

programs that resulted in $100MM market penetration. Entered customer's

"Hall of Fame" and achieved "Outstanding Supplier" awards from key

customers.

. Led effort to develop strategic plan to automate manufacturing facilities

resulting in efficient supply chain, cycle time reduction, process yield

improvement, inventory reduction and production optimization.

. Re-engineered customer complaint process through design, development and

implementation that resulted in $10MM savings and 75% reduction of

workflow.

. Established Comprehensive Supplier Development Programs to significantly

improve supplier performance to 80%+ and to drastically reduce COPQ 60%+

resulting from supplier non-conformances.

. Developed and introduced customized in-house quality, technical, and

regulatory training for employees, suppliers, and customers, generating

up to $1M in cost savings while increasing efficiency as much as 40%.

Trainings include Lean Six Sigma, Green Belt & Black Belt; UL ratings,

FDA Regulations etc., CE Markings; TS16949, ISO9001, ISO14001 etc.

standards; Business Quality Excellence 101 & 102; COPQ, VA, VE, VSM, 8D,

5 Whys, PSDM, TQM, TOC, TPS; Shainin & Shingo techniques; and Automotive

Core Quality Tools APQP, PPAP, FMEA (DFMEA, PFMEA etc.) DOE, SPC, MSA

etc.

. Saved up to $2M in annual costs by setting up in-house labs using

existing resources, significantly improving response and cycle times

while eliminating the need to send samples to outside labs for testing.

Implemented automations and information management systems, specifically

LIMS, PIMS, and QSI systems, that increased overall productivity up to

65%, improved on-time delivery from as low as 65% to 100%, saved up to

$1.6M in costs, and added as much as $5.8M in revenues.

PROFESSIONAL EXPERIENCE

Elcoteq Inc., Richardson, Texas May

2004 - Present

Global Quality Director

Provide QA/QC, Reliability and Engineering leadership to a Fortune 500

global manufacturing organization as a member of the management team.

. Established quality vision, mission, quality policy, short and long-

range strategic objectives to achieve profit, growth, world class

quality and related organizational objectives. Achieved desired

results through cross-functional teamwork, quality trainings, audits,

management reviews, regulatory compliances, CAPAs, budgets, efficient

supplier quality management, effective decision-making, continuous

communications and continual improvements. Lean six sigma implemented.

Coordinated and performed several six sigma projects. Reduced waste,

reduce warranty costs, COPQ, improved product and process efficiency,

improved supplier/outsourcing quality performance, increased customer

satisfaction etc. to improve business quality excellence. Obtained

"Strategic Enterprise" ISO9001, NADCAP, AS9100, EASA, ISO/TS16949,

ISO/TS29001, APIQ1, ISO13485, ISO14001, OHSAS18001, SA8000, and

ISO17025 certifications to global facilities. Introduced "Gemba" to

improve manufacturing, organizational and overall business

performance.

Umesh N. Rao

Page 2

Praxair, Inc. (formerly Union Carbide), Richardson, Texas

Apr. 2000 to May 2004

Global Quality Director

Provided QA/QC, Reliability and Engineering leadership to a Fortune 500

global manufacturing organization as a member of the management team.

. Established quality vision, mission, quality policy, short and long-range

strategic objectives to achieve profit, growth, world class quality and

related organizational objectives. Achieved desired results through

teamwork, quality trainings, audits, management reviews, CAPAs, budgets,

efficient supplier management, effective decision-makings, and continuous

communications. Obtained ISO/QS9000 "Strategic Enterprise Certification"

within10 months to 28 global facilities. Implemented supplier quality

developments and improved customer satisfaction. Reduced warranty costs,

reduced COPQ and improved quality operations and efficiency. Obtained

AS9100, NADCAP, APIQ1, ISO/TS29001, ISO14000 certification to global

facilities.

. Six Sigma Black Belt/Champion. Developed and maintained strong

relationships with suppliers and customers in an effort to proactively

provide best problem solving solutions for both internal and external

customers to improve business profits.

Huntsman Corporation, Longview, Texas Nov.

1992 to Apr. 2000

Quality Director

QRE/QA/QC and technical decision-maker for a Fortune 500 global

manufacturing company. Member of the management team responsible for

developing and executing company's quality and technical strategies.

. Managed multi-million dollar product development effort. Led all quality

systems and technical workflow processes within Huntsman Corp. Obtained

QS9000, AS9100, NADCAP, APIQ1, ISO/TS29001, ISO1400 & ISO25 "Strategic

Enterprise" Certifications. Achieved desired results through teamwork,

quality trainings, audits, management reviews, CAPAs, budgets, efficient

supplier management, effective decision-makings, and continuous

communications.

. Served as knowledge leader in Six Sigma Projects. Met with client

company's Executives and formulated comprehensive plans to develop

quality and technical strategies based on client specifications.

. Key person in implementing Lean Manufacturing and Problem Solving

Techniques within ongoing operations that effected advancement and

development of quality and technical issues.

CERTIFICATIONS

. Certified Six Sigma Black Belt.

. Lean experienced, facilitated and implemented.

. Certified Train the Trainer.

. ASQ Certified Manager of Quality/Organizational Excellence (CMQ/OE).

. ASQ Certified Quality Auditor (CQA).

. ASQ Certified Quality Improvement Associate (CQIA).

. RAB/IRCA Certified ISO/TS29001 Lead Auditor.

. RAB/IRCA Certified ISO/TS16949 Lead Auditor and Internal Auditor.

. RAB/IRCA Certified ISO9001:2008 Lead Auditor.

. RAB/IRCA Certified ISO14001 Lead Auditor.

. RAB/IRCA Certified OHAS18001 Lead Auditor.

. RAB/IRCA Certified AS9100C Internal Auditor.

. RAB Certified QMS (Quality Management System) Provisional Auditor.

. RAB Certified EMS (Environmental Management) Associate Auditor.

. AIAG Certified ISO/TS16949 Supplier Auditor.

AUDITS

Developed and implemented quality system audits, process audits, product

audits and supplier audits. Co-ordinated and facilitated registrar,

regulatory, customer and other audits.

PRESENTATIONS AND TRAININGS

Developed and implemented several quality trainings/presentations to

employees, suppliers and customers.

PUBLICATIONS

Thirty two (32) publications in reputed professional &

technical journals.

PROFESSIONAL MEMBERSHIPS

Fellow of the American Institute of Chemists (FAIC). Member of ACS,

API, ASTM, ASQ, APICS etc.

COMPUTER SKILLS

Microsoft Office, Microsoft Project, SAP, Lotus Notes, QSI software, SMS, Q-

CIM, LIMS, PIMS,

Visio, SPC software, NWA, Minitab, Statgraphics etc.

EDUCATION

Ph.D. (Organic Chemistry) - University of Wisconsin, Wisconsin.

M.S. (Analytical Chemistry) - Ohio University, Ohio.

B.Sc. (Chemistry, Physics and Mathematics) - Andhra University, India.

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