Quality Continuous Improvement

RESUME

CURRICULUM VITAE

SRINIVAS PAI .G

(Contact: +91-998**-*****)

E-mail: ************@*****.***

Seeking a technically challenging position in area of Automobile Engineering, providing a highly motivated, progressive, friendly environment, encouraging the pursuit of career advancement and expand my knowledge and skills.

Career Summary

17 Years of Domain expertise in leading Automobile Companies like Toyota, & Volvo .

Core Competencies at a Glance : In Operation’s

Quality Function Inspection system set up

Tool Tryout & Commissioning

Well versed in Lean manufacturing, Toyota production system (TPS) & Implementation

Production Efficiency /Productivity Enhancement

Quality Assurance,7 QC Tools & 4M analysis

Global leadership in Safety, Cost & Quality

FUNCTIONAL SKILL SET : Operations with Lean / TPS

Manufacturing Tools & Technique

Lean TPS Visual Management

Standard Work Process Mapping 5-S

Operation ‘s Quick Change Over Andon,Jidoka

A-3 & A-4 Report PDCA & Work Audit

Core Strength :

-Fast learning curve to adopt new concept /technique / new environment /Process

-Experienced in Q C, built in quality assurance systems, quality networks through PDCA &TQM

-Proven Team Leadership Quality

-Result oriented with in Target Time frame

-A versatile communicator with both team building & managing skill

-Accelerated Human development management with bottom up approach

Education Qualification

Completed Diploma in Automobile Engineering in the year- 2010 from

The Oxford Polytechnic, Bangalore.

Completed Industrial Training Course in Mechanic Motor Vehicle in the year- 2000 from

Sri Dharmasthala Manjunatheshwara Industrial Training Institute (S.D.M.ITI), Venoor, Karnataka.

Apprentice Training Scheme

Successfully completed the Apprentice Training Scheme recognized by the Government of Karnataka- 2002.

Professional experience in Domain

Toyota Kirloskar Motor Pvt. Ltd.

Plot No.1, Bidadi Industrial Area,

Ramnagara District,Karnataka-562109,

Ph.No: +918*-********,

From: 27th September, 2002 to 13th November, 2017

Designation: Team Member Leader

Department: Quality Control Division

Reporting To: Team Leader,

Job: Full Time

Salary: Rs 53,800/-.p.m.

After having completed my Apprenticeship on 25th April, 2002, at Volvo India Pvt Ltd, I was offered Full Time employment in the company on 27th September, 2002 and continue to work till 13th November, 2017. As a Team Member I have worked in different areas like Function inspection, Vehicle audit, vehicle investigation and repair, reworking of rejected parts.

As a Team Member my Key functional responsibilities are as follows:

Vehicle functioning - inspection.

Defective vehicle investigation vis-à-vis vehicle from production line & customer complaints defects (warranty parts) & Repair of vehicles which are investigated.

Post investigation - documentation of defective parts supplied by vendor

Production department process quality audit (In process audit).

Vehicle regulation confirmation as per BIS standards

Reworking of parts which are rejected.

Assembling the parts by referring to the Toyota master specification sheet

My work duties have to follow TOYOTA STANDARDS which are defined for different vehicle models of Toyota

FUNCTION INSPECTION:

To ensure that performance norms are met from safety perspective, by testing for all the vehicle parts. I carry out the following inspections :

LSPV-LOAD SENSING PROPORTIONATE VALVE (LSPV)

I carry out this test for different braking force proportionate to the load, to stop the vehicle within braking distance. LSPV is adjusted by using LSPV adjuster equipment

FWA- FRONT WHEEL ALIGNMENT (FWA)

I do FWA to see that (a) vehicle does not pull to one side (b) proper steering stability is there (c) there is no excessive vibration (d) no excessive tire wear. For this I carry out the following adjustments in FWA process by using Wheel Alignment Equipment:

1) Adjusting the camber angle

2) Adjusting the castor angle

3) Adjusting the Toe-in Toe out

4) Confirmation of adjusted camber, castor angle & Toe

HEAD LAMP ADJUSTMENT & S/T ANGLE INSPECTION

I adjust the head lamp height & aiming in this process, check the head lamp function. I adjust & check the S/T angle. This inspection comprises of

1) Confirmation of ST angle with the help of equipment & Adjusting if needed

2. Adjusting of RH & LH head lamp with the help of equipment as per standard

3. Confirmation of headlamp function & dim-dip function by using head lamp equipment.

DRUM TEST & BRAKE TEST : I carry out this function with the help of drum & Brake Tester equipment

1)Proper functioning of all lights & lamps ( H/L, RR combination lamp, tail lamp, lamps of dashboard)

2)Proper clutch functioning. i.e. clutch noise, clutch spongy

3)Proper brake functioning. i.e. brake noise, brake spongy etc

4)Running the vehicle at different speeds in stationary condition with the help of equipment ( 0 to 120 kmph)

5)Inspection of proper gear shifting, double gear engaging, gear shifting noise, gear shifting hard,

6) Confirmation that vehicle not dragging during braking

7)Confirmation of ABS (stopping distance, ABS actuated for all wheels equally)

8)Confirmation of body vibration at different speed, within specified vibration tolerance

9)Confirmation of transmission noise, propeller shaft noise, suspension noise within specified parameters

10)Confirmation of Tyre noise, S/T off center

11)Confirmation of S/T post tilting function, S/T rotation noise

12)Confirmation of combination meter function (speedometer, odometer, temp. gauge etc) and all indicators

13)Confirmation of Park Brake force.

UNDERBODY INSPECTION

Inspection of underbody parts such as suspension, transmission, exhaust system, steering

System etc for:

1) No LLC spillage, No oil leaks

2)Confirmation of underbody specification

3)Confirmation of S/T gear box boot tilt

4)Confirmation of no looseness for all bolts & nuts

5)Confirmation of torque of some underbody parts ( safety related)

6)Confirmation of clamps, clips, connectors, earth wires at underbody

ENGINE ROOM INSPECTION

In this function I carry out engine room inspection by using Multi Inspection equipment (MI Tester) for 5,6.7.8,9,10.11.. Other functions are visually inspected

1)LLC, Oil leak inspection in E/G room

2)LLC, Engine oil, P/S oil levels

3)Confirmation of wires interference, hose interference

4)Any abnormalities in E/G room during running

5)MI inspection (Multi information)

6)Confirmation of proper function of clutch, ECU, brake etc with the help of equipment

7)Confirmation of EFI check mode (Electronic Fuel Injection) with the help of equipment

8)Confirmation of Injector Injection quantity with the help of equipment

9)Confirmation of TCS diagram (Traction Control system) with the help of equipment

10)Idle inspection with the help of equipment

11)Immobilization inspection with the help of equipment

DYNAMIC CHECK:

This is applied to all functional defects during driving like Engine Stall & Abnormal idle revolution (High or Low). This is carried out in standard test track, rope road, bump road, & sine wave.

1)Confirmation of basic performance of the vehicle Steering, Running & Braking of manual & auto transmission vehicle according to the Toyota driving pattern procedure.

2)Testing proper functioning of all parts during driving

3)Confirmation of no over running, no engine stall

4)Confirmation of Drivability, Ride comfort, steering stability and controllability

5)abnormal noise from interior parts,& exterior parts in rope road driving and sign wave driving

6)Confirmation of no steering off center, braking effect ( G max brake) no pulling to one side,

7)Confirmation of operation feeling ( lateral movement, free play) - of clutch pedal, brake pedal, accelerator & steering rotation, gear shift lever operation

8)Testing of ABS ( Anti Locking Braking System) in slippery road

9)Confirmation of speedometer gauge needle vibration, during driving

10) confirmation of N V H ( Noise Vibration Harshness) : no booming noise, no bearing noise, Take off vibration, engine noise, idle vibration, cranking vibration, body shake, Brake vibration, road noise, transmission gear noise, Differential gear noise, harshness.

DEFECT INVESTIGATION (CHOSA-GUMI) and REPAIR

1)It is a department which supports the Engineers to take the countermeasure for the problems (defects) like production vehicle defects and customer complaint defects (warranty parts). Investigation, analyze, finding route cause and repair for the defects is my responsibility. After completion of investigation and repair I prepare a report which contains all the details & submit it to Quality Engineering department.

INVESTIGATION ACTIVITY IS CATAGARISED AS FOLLOWS

1)Electrical investigation

2)Trim investigation

3)Function investigation

4)Water leak investigation

ELECTRICAL INVESTIGATION

Electrical investigation is carried out if the electrical circuit & electrical parts gets any problem (Not working, Malfunction, etc). Investigation is carried out by using intelligent tester, Ohmmeter, Voltmeter, Ammeter, Multi meter & Electrical Wiring diagram. The problems with following systems are related to electrical investigation.

ELECTRICAL INVESTIGATION STEPS:

I use intelligent tester to find out the code with respect to the electrical circuits each circuit is assigned a code. When the code is displayed in the intelligent tester, I check the circuit diagram with the help of EWD (Electrical Wiring Diagram). After this I

1)Check the condition of fuse and relay.

2)Check the connectors for half lock, damage, pin bend, terminal back out.

3)Use multi meter/ voltmeter/ Ohmmeter/ Ammeter to check circuits, Voltage check, current continuity & resistance, short circuits etc.

4)Finding route cause.

5)Repairing or replacing the defective parts.

6)Preparing a report and submitting it to Quality Engineering department.

7)Returning the defective parts with the report.

FUNCTIONAL INVESTIGATION

Function investigation is carried out if the mechanical parts have problem (Not working, Malfunction, etc). And also for noises during operation, body vibration, Problem in driving performance of the vehicle, engine problem, not working as per the standard etc. I carry out Investigation by checking the suspected parts one by one with the help of manuals.

1) Engine

2) Suspension system 3) Transmission system (Clutch, Gearbox, Drive axles) 4) Steering system 5) Braking system

MECHANICAL INVESTIGATION STEPS

1)Analysis of the defect

2)Taking trials

3)Finding route cause

4)Repairing or replacing of defective parts.

5)Preparing a report and submitting it to Quality Engineering department.

WATER LEAK INVESTIGATION

Water leak investigation is done on vehicle in which water enters inside the vehicle during water leak test. Water at high pressure is forced on the vehicle (through nozzles) from all directions. Water should not enter inside the vehicle. But sometimes due to body defect water enters into the vehicle. This vehicle body will be compared with the standard & body problem will be identified & resolved.

WATER LEAK INVESTIGATION STEPS

1)Analysis the defect

2)Taking the body measurements by using vernier caliper, micrometer, ball gauge, feeler gauge, levelness gauge etc

3)Comparing the body fitment of the vehicle with the standard

4)Finding route cause

5)Repairing or replacing defective part.

6)Preparing a report and submitting it to Quality Engineering department.

TRIM INVESTIGATION

Trim investigation is related to body fitment defect, uneven clearance, unlevelness, part fitment problem, connector not locking, part coming off, wire interference etc with reference to cvics.

1)Analysis the defect

2)Taking the body measurements by using vernier caliper, micrometer, ball gauge, feeler guage, levelness gauge etc

3)Comparing the body fitment of the vehicle with the standard

4)Checking the part profile, drawings etc

5)Removing the parts & fitting another parts, fitting the defective parts to other vehicle (Taking trials)

6)Finding route cause

7)Preparing a report and submitting it to Quality Engineering department.

DOCUMENTATION OF SUPPLIER QUALITY PROBLEM:

Generating daily reports on the quality related issues & updates of the components to the Quality Team Leaders & Engineers.

PRODUCTION DEPARTMENT PROCESS QUALITY AUDIT (INPROCESS AUDIT).

Inprocess audit is the processes of auditing various assembly processes, weld processes, and paint processes. It includes auditing tool calibration, IQPR countermeasure auditing etc. The details explained below. The main purpose of the auditing is to confirm proper sequence of operation, Quality of operation, Operation as per STD, proper method etc. Only one vehicle per day will be audited (Random check). I carry out the following audit checks:

1.Auditing the weld shop processes – welding defects ( spot & co2 weld)

2.Auditing the weld shop two hour check data

3.Auditing the assembly shop processes for proper sequence

4.Confirmation of paint quality in paint shop (Thickness, glossiness, ED thickness etc.)

5.Tool calibration auditing of assembly shop

6.Torque confirmation of safety related parts

7.Confirmation of wax application

8.Preparing IQPR (Internal Quality Problem Report)

9.Auditing of IQPR countermeasure

VEHICLE REGULATION CONFIRMATION AS PER INDIAN STANDARD

Confirming brake stopping distance, vehicle emission confirmation, vehicle head lamp height confirmation, steering effort confirmation, Speedo meter calibration, vehicle minimum turning radius confirmation, vehicle dimension measurement, vehicle weight checking, fuel system leak and vent test etc.

REWORKING OF PARTS:

Doing reworking of parts which is rejected during the inspection, parts which having problem in fitment, and the parts which are rejected while doing assembly. I re-work on the rejected parts (minor defects)

ASSEMBLING THE PARTS AS PER SPECIFICATION & OTHER ACTIVITIES :-

1)Assembling the reworked parts according to the specification.

2)Quality control circle: As a member of this circle I was involved in solving the problem by using 7 QC steps & Tools.

3)Toyota Production System (TPS): (a) Continuous improvement, Just in time production (JIT), Jidoka, Pokayoke, KanBan system, Heijunka ( leveled production), Continuous flow processing, Standardized work, Jumbiki system, Management of MUDA, MURI, MURA

4)Toyota way: Toyota work culture

5)Kaizan ( continuous improvement)

6)Cost: reduction by power saving, minimizing consumables, Value addition & value engineering

7)FMDS (Floor Management development system )

8)Environment awareness: making environment Kaizan’s, waste management, following ISO 14001 standards

9)Environment Kaizan’s

10)Latest automobile technology ( Airbag, A&S, EBS,EPS ETC)

11)Safety& Firefighting training programmes

12)Prepare PPM and DPV Reduction in Function Line. And solve any arising issues in the assembly line area with regard to material. Ensure timely preparation and furbishing of the investigation report for the concerned department.

13)Leading a team to achieve departmental targets KPI in production, quality, cost and safety.

14)Responsible for execution of given departmental targets as per Hoshin Kanari (Company Policy) for the group performance

15)Responsible for the Implementation of Toyota Production System Viz ., Just in time, one piece flow system, 5S, Built - in - Quality, Standardized work, Total preventive maintenance (T P M )

16)Monitor QIR and Counter measures from the Vendors.

17)Accountable for undertaking all KAIZEN (Continuous Improvement) related activities i.e. providing value added suggestions for improving the quality which in turn leads to process improvement and safety.

18)Training and Development aspects of the team consisting of activities to meet environmental standards, skill improvements, personality development of team members, work instruction chart, instruction drawing and Instruction display for the smooth flow of production

19)Ensure adherence to PDCA (PLAN, DO, CHECK, ACTION) cycle.

20)Responsible for HIYARIHATTO (Recognizing near missed Accidents) activities which includes following and implementing SOP (Standard Operating Procedure) and recognizing unsafe areas in the quality line that hinder the delivery of the quality product and also correspondingly suggest safety measures.

21)Managing all activities pertaining to Quantity Surveying, Quality Control and involved in day to day monitoring of progress of work.

22)Responsible for checking the quality of all incoming raw materials, ISO Documentation and labour management.

Key Achievement’s: Toyota Kirloskar Motors Pvt. Ltd.

1.Successfully completed training in Receiving Inspection and Work Place Safety Sessions

2.Also completed trainings in First Aid, TPS and 5S

3.An active participant in the Quality Control Cools (QCC)

4.Participated and won numerous awards in Inter-department sports activities

CORE COMPETENCIES :-

● Chousa Gumi (Investigation) ● Kaizen (Continuous Improvement) ● Hiyarihatto (Recognizing Near Missed Accidents) ● Quantity Surveying ● Quality Control ●

Volvo India pvt Ltd, Bangalore.

M/S VOLVO INDIA Pvt Ltd, an ISO 14001 company, in India, manufacturing high quality trucks & buses for its customers. The company situated at yalachahalli, about 15km away from hosakote having auto body manufacturing and assembly plant. The Company had started its production in the year 1999 with yearly capacity 1,500 units of trucks like FH-12 (6X4),FM-7(8X4) & B7R Buses it also had its construction equipments like excavators, hullers, and Marine engines.

25th Apr’ 01- 25th April’ 02 National Apprentice Certificate – Mechanic – Motor Vehicle

Apprentice training at VOLVO INDIA PVT LTD :- Paid Apprenticeship

Apprentice Trainee

Involved in all activities pertaining to Assembly Main Line which included Assembling of Chassis, Hose Routing, Pre Assembling of Rear Axles, Assembling of the Rear Axle to chassis, Mounting of the Engine and Gear Box and Mounting of Cab to Chassis.

Managed materials in Stores, operated Stackers and Forklifts, maintained the Stock register (Data Base) for the incoming and outgoing stocks and supported the assembly main line and After Market Division (Service Department).

Scrutinized trucks and examined the performance of the trucks on the test track. Thereafter, provided defect feed back to Assembly Line (Production).

Acted as a Trainer for the Quality inspection department.

Involved in planning and the analysis of post - production problems.

Personal Details

Marital Status : Married

Children : 2kids

Passport no : P 7 3 2 6 4 9 7

Date of Birth : 16th March, 1982

Languages : English, Hindi, Kannada, Tulu, Konkani

Permanent Address : 23-9-727, “Sharada Prasad”,

Pai’s Compound, Mangaladevi Temple Road,

Jeppu, Mangalore-575001.

I do hereby declare that the information given above is true and correct to the best of my knowledge

(G.Srinivas Pai )

Date:

E-mail: ************@*****.***

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