Quality Engineer

Abdur Razzaq

***-****** ******

Waterloo, Ontario N2V2T8

Ph(H):519-***-****,Ph(Cell):519-***-****

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

CAREER OBJECTIVE:

Seeking a challenging position in the fields of Quality Assurance/Manufacturing in an organization where my skills and knowledge can play a pivotal role in the upward progress of the company.

EDUCATION AND TRAINING:

1992M.Sc. Metallurgical Engineering

1983B.Sc. Metallurgical Engineering.

2014 Think on Your Feet.

2014 Lean Supervisor.

2013 Effective Problem Solving.

2012 Communication with diplomacy.

2012 Customer Service Training.

2010 Welding Supervisor Seminar & Exam.

2006Internal Auditors Training for TS:16949.

2005 Internal Auditors Training for ISO:14001.

2006 Process Failure Mode and Effects Analysis (FMEA).

2005Understanding and Implementing ISO/TS 16949:2002.

2002 Training on MSA 3rd Edition.

1998Certified Lead Auditor for ISO:9001.

1993Ultrasonic Inspection, Magnetic Particle Inspection, Radiography, Heat Treatment Analysis,

Gauges Calibration and Control Techniques, Systems and Procedures (Massey Ferguson-UK).

1989Different techniques of Heat Treatment and Metallography.

1988Mechanical Testing, Metallography, N.D.T Procedures (Massey Ferguson-UK).

PROFESSIONAL SKILLS:

Licensed Professional Engineer (P.Eng.).

Certified Lead Auditor for ISO: 9001.

More than 30 years of experience in QC / QA and Quality Improvement in an OEM and Tier-1 Manufacturer/Supplier.

More than 20 years of Supplier Development experience

Goal Oriented, Loyal and Team Player professional with strong Analytical abilities.

Positive Professional with excellent Conflict Resolution abilities

Strong Communication and Interpersonal Skills.

Excellent Prioritizing Skills and determined to Meet the Deadlines.

Specialization in Failure Analysis, Metallography and Analysis of Heat Treated Components.

Working knowledge of M.S Word, Excel, Power Point, Project and Internet

TECHNICAL SKILLS:

Extensive experience of ISO: 9001, TS: 16949/QS: 9000, ISO: 14001 gained while working for different registrars and as a MR for multinational companies.

Competency in M.S.A(Gauge R&R, Linearity, Bias and Stability) and gauges calibration achieved through training and working at Niagara Machine Products,Bodycote Thermal Processing and Cascade Corporation.

Well conversant with Quality Tools (X-bar,R chart,Cause-effect-diagram,Pareto analysis).

Excellent experience of SPC including Micronite, Minitab and QC-Pro. 8-D process gained at NMP, Bodycote,Cascade, Millat Tractors and Cascade Corporation.

Excellent Problem Solving skills demonstrated by conducting failure analysis of transmission gear and pinion at MTL, transmission valves at NMP and Forks at Cascade Corporation.

Cost Saving skills proved by reducing lab. expenses from 120K to below 80K at NMP and by maximizing furnace loads at Bodycote and optimizing the heat treatment process at Cascade Corporation.

Continuous Improvements skills demonstrated by installing PD-5 on grinding lines, short feed sensors and diverters at screw machines at NMP.

Excellent Time Management and Organizational skills demonstrated by maintaining TS: 16949, ISO: 14001, KPIs reporting to Corporate and plant management, training of employees, interaction with customers on quality related issues and quality audits responsibilities in parallel.

Well-conversant with FMEA, Process Flow Diagrams, Control Plan, APQP, PPAP, and G.D&T.

Working knowledge of JIT, Quick Changeovers and 5S.

WORK EXPERIENCE:

Cascade Corporation-Canada &USA

Quality Manager North America and Corporate Metallurgist June 2008 to May2016

Oversee Quality Assurance of two fork manufacturing facilities, one in Canada and the other in USA.

As a Management Representative, Organize, Manage and Maintain QMS for both facilities.

Organize and Chair Management Review Meetings on monthly basis.

Liaison with customers on warranty, liability and quality related issues. Approve suppliers and conduct audits.

Provide guidance to other Cascade facilities (globally) in material selection, heat treatment, welding processes and quality issues in particular with forks.

Frequently travel to USA and China to provide technical guidance to improve the quality of forks being manufactured in Cascade’s facilities.

Evaluate and select suppliers globally (China, Brazil, USA and Canada) and monitor suppliers performance on ongoing basis.

Interact and communicate with corporate on product quality and performance data on regular basis.

Review functionality and failure data of forks from all six fork manufacturing facilities(UK, Italy, China, USA and Canada)

Increased throughput by optimizing the induction heating, welding and heat treatment processes.

Developed and implemented procedures to qualify welders by internal testing and by CWB.

Organized functionality tests of forks to comply to manufacturing and safety standards.

Performed failure analysis of customer returned forks to settled warranty claims.

Developed and implemented in process audits on daily basis.

Bodycote Thermal Processing-Kitchener (Tier-2 Supplier) July 2005 – March 2007

Quality Manager

Implementation and Certification for TS: 16949 and ISO: 14001.

Planned, Managed and Conducted Internal Audits (Job, Dock, Layered and Process Audits).

Trained Internal Auditors. Provided in class as well as on the job training to employees.

Updated and monitored KPIs(Cost of Quality, PPM, Delivery, Sales, and Equipment Utilization etc) on monthly basis. Presented to the Corporate as well as Plant Management for review. Developed action plans.

Liaise with Customers and Suppliers on quality issues including source inspection, audits and process surveys and corrective actions.

Monitored Corrective Actions (Internal and customers).Completed 8-D and issued quality alerts.

Developed PFD, Control Plan, PFMEA and submitted PPAP to the customers.

Monitored process variables(C%, Time & Temp.) and Product quality (Hardness & Case depth) utilizing X-bar, R chart and capability (Cp& Cpk).

Conducted cross functional daily morning meetings to discuss and resolve previous shift issues (Internal and External).

Increased productivity using optimum sized loading fixtures(Baskets)

Enhanced Furnace utilization through error proofing (pre-loading gates).

Supervised Quality Engineer and Quality Inspector.

Established Material Testing Lab. With new Rockwell (Regular and Superficial) Hardness Testers, Cut off machine, Grinder/Polisher, Mounting Press and Micro hardness Tester.

Niagara Machine Products-St. Catharines (Tier-1 Supplier)

Quality Supervisor/Quality Engineer March 2002-June 2005

Performed Layout, Capability Study(CP & Cpk) and MSA(Bias, Linearity and Gauge R&R) for PPAP.

Actively participated to launch GF-6 program(Six speed valves for GM Korea)

Increased profitability through cost saving and scrap reduction by implementing Error proofing projects such as PD-5 on grinding lines,short feed sensors and diverters on screw machines

Reduced lab. expenses from 120K to below 80K performing in-house calibration and introducing accurate and user friendly gauges.

Performed root cause analysis to solve heat treatment and machining problem for 4049 valves.

Managed the facility Lab., Testing and Metallurgy activities.

Supervised, trained, provided directions and conducted performance review of 4 Quality Inspectors.

Performed and monitored Gauges Calibration using QC Pro.Software.

Hands on working with Optical Comparators, Super Mics., Dia Met, Perthometer, Permascope, Form Tester and other measuring instruments. Performed microstructure analysis of heat treated parts.

Performed Sediment Testing as per G.M, Ford, and Honda Specifications.

Massey Ferguson Corporation (OEM)

Quality Manager Jan. 1995-Jan.2002

Supervised 7 Engineers and 12 Quality Inspectors plus 2 supporting staff members.

Management of Quality Control Department (including hiring, deployment and training of employees).

Updated KPIs and presented to the management during monthly review meetings.

Developed Suppliers through training, process review, QMS auditing and monitored their performance on quality and delivery basis.

Ensured that BOF parts are defect free and met the specifications from the Metallurgical and Dimensional point of view.

Tracked Warranty claims of field failures, developed action plans and implementation to keep the warranty cost below the target (2.5%).

Established strong interaction with Dealers/Customers to incorporate their voice to improve quality of product/services.

Conducted Failure Analysis of Transmission Gear and Pinion. Implementation of my recommendations reduced the failure rate by 5 % over a period of one year.

Massey Ferguson Corporation (OEM)

Quality Engineer (Lab. and Gauges Calibration) Sep. 1986 – Dec. 1994

Established and managed testing labs.

Performed hardness, tensile, impact and traverse testing. Metallography and gauges calibration.

Performed chemical analysis of ferrous and non-ferrous tractor parts using wet analysis and colorimetric methods.

Performed hardness, accelerated aging, volume expansion, and collapsibility and burst testing of rubber parts/hoses.

Performed gloss, flexibility, adhesion, color matching and salt spray testing of painted, plated, and phosphated parts.

Reviewed test results and reports prior to issuance.

REFERENCES:

Available upon Request

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