Sign in

Manager Quality

Pune, MH, India
Acceptable as per company rules and regulations-
March 22, 2018

Contact this candidate


Prakash M. Khankale

Contact No.: +91-916******* & +91-883*******


A seasoned & result driven professional with 24 years of extensive experience in Quality department in Forging Industry including machine Shop.

Expertise in quality system implementation, quality assurance, quality control, TS-16949 system implementation along with proper quality management & documentation, PPAP, QMS, TQM, New Product Development, APQP, gauges planning, manpower planning, CMM room management, preparing control plan, Instruments & gauges management system, Handling customer complaints, 8Ds, CAPA. Extensive experience in forging industry quality issues, their remedies & customer requirements or salvage plan. Worked in machine shop and managed complete documentation, gauge plans, final inspection, stage inspection, dock audits & supplier quality developments. Interacted with various prestigious customers for understanding their correct requirement, handling and closing customer feedback with proper and systematic approach & documentation. Work experience in different Project working from Production, Quality and Maintenance like Set up time reduction, Productivity Improvements, Job establishment time reduction, Cycle time reduction, Internal and External rejection reduction, Customer Complaint Reduction etc,COPQ reduction, Man Power Rationalization etc.


Forging process knows how and its quality improvement plans.

New product development gauges plan, inspection process decision making.

Process Validation & supplier quality developments.

Knows to design special functional gauges for correct output with adherence to drawing requirements.

Review & analysis of CMM reports.

Identifying discrepancies in process & to suggest improvement action plan.

Handling of all inspection instruments.


Front Axle Beam, Crank Shaft, Connecting Rod, Cam Shaft, Stub Axle, Links, Gears, Saddles, Flanges, Yoke, Short Fork, Eye Bolts, Hub, Pinions, Crown Wheels, Rear Axles, Etc... ORGANISATIONAL EXPERIENCE

1] Since March’16 @ Metalyst Forgings Limites, Aurangabad, Maharastra,#General Manager-(Quality Dept.-Forgings + Machining).

2) 2.0 Years @Ramakrishna Forgings Limited, India-JSSR#General Manager (QA.-Forgings+ Machining)-Green Field Project (New Plant Establishment). 3] 2.0 Years @ FAW-Bharat Forger Company Limited, China # Senior Manager (QA) - Green Field Project (New Plant Establishment).

4] 3.0 Years @ International Auto Limited, Bhubaneswar # Sr.Manager (QA & System Implementation)

- Green Field Project (New Plant Establishment).

5] 1.0 Years @ Bharat Forge Limited, Pune # Manager (Quality Department). 6] 2.0 Years @ Ahmednagar Forging Limited, Pune # Manager (Quality Department). 7] 2.0 Years @ Amforge Industries Limited # Dy. Manager(Quality Department). 8] 11.0 Years @ Bharat Forge Limited, Pune # Dy. Manager (Quality Department)-Career started from January-1992.


Interacted with various customers for New Component Development, Quality Plan, PPAP, handling NCs, customer complaints & other development activities in Forging shop and Machine Shop. Some of valued customers like:-

Maruti Udyog Limited (MUL), Daimler India Commercial Vehicles (DICV), General Motors (GM), Renault, TATA Motors, Mahindra & Mahindra (M&M), Bajaj Tempo, Bajaj Auto, JCB India, AMTEK, Endurance, Carraro India, American Axle Manufacturing (AAM), Spicer India Limited (SIL), DANA India Limited, Brakes India, Caterpillar, IVECO, DANA, USA. WUXI, China. KEY RESPONSIBILITIES HANDLED

Quality Planning:-

Define & Implementation of Quality KPI for Central and Site function

Define quality system requirements Master SOP document

Monitor SOP being implemented at site

Regular review, updating and control of SOP for Central & site locations.

To initiate management review and report the key performance index on customer concerns, corrective & preventive action and trends for improvement.

To develop quality plan and ensure full implementation in operations.

To manage customer concerns and ensure the effectiveness of all response, including response time to customers.

To ensure company activities fulfill HSE requirements and regulation. To initiate training or programs in order to reduce risk level, accident rate and energy consumption in the company.

To co-ordinate Business Excellence activities

Quality Audits & Customer complaint handling:-

Conduct periodic quality audits at the plants, Develop Audit plan, Audit Schedule, conducting system / Process / Product / Audits.

Co-ordinate External quality & Intra site audit matrix for all sites.

Coordinating with sites for timely closure of corrective actions on Audit gaps-internal & external.

To lead the internal quality audit, report to management the results and follow up on the corrective actions.

To oversee the daily quality activities such as incoming/ outgoing inspection and process audit.

To conduct supplier audits and qualify the process capability as well as QMS effectiveness.

To monitor supplier quality performance and initiate review meeting with the suppliers.

To involve in the design and implementation of supplier development programs.

To manage customer concerns and ensure the effectiveness of all response, including response time to customers.

Quality-Execution & System Implementation:-

Monitor and review quality; basis specification as per requirement- experience as a HOD-QA & system.

Provide conditional acceptance to plant where required and coordinates with procurement team for resolution of issues.

To implement and maintain ISO 9001, QS 9000, ISO 14001 & ISO/TS 16949 management system for the company.

To conduct SPC and other quality tools training for operations. Assist Engineering in analyzing SPC reports and propose improvement plan.

To provide analysis on Cost of Quality for management & improvement.

To improve inspection effectiveness as well as efficiency by introducing cost effective measuring system or equipment such as gauge design.

Responsible for multiple locations overall quality functions & improvements.

New Product Development & Supplier Quality Development:-

Products development support.

Coordinate for QMS connectivity & implementation to plants.

Co-ordination with other departments for higher productivity & utilization.

Coordinate with packaging to undertake change requirements for new parts as per requirement.

To collect and analyze quality records and develop improvement plans.

To lead the task team in failure analysis, problem solving and design appropriate corrective and preventive actions.

To assist the submission of PPAP for customer approval with GR&R, SPC, etc.

Expertise in entire process from new part development to production ramp up.

People Development

Setting direction, energizing, and mentoring, coaching, motivating, guiding and supporting teams.

Competencies Assessment of Executives & Managers, conducting talent reviews & recruitment.

Developing, managing and monitoring the performance of multi-skilled large work force and conceptualizing need-based training programs for performing maintenance operations. EDUCATIONAL:-


Other education:-BA,DIT, CAD-Pro-Eng., ISO9001:2000 QMS Lead Auditor Course


In China, Worked with FAW-Bharat Forge Limited for two years, where actively participated as the forging expert and system implementation. Handled customer complaints of Bharat Forge Ltd., Pune in China.Company has appreciated for the same. PERSONAL DETAILS

Date of Birth: 30 June 1971

Languages English & Hindi (Fluent) and Marathi (native fluency) Address :- Singhagad Road, Dhayari, Pune-411014, Maharashtra, India

Contact this candidate