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Engineer Quality

Asheville, NC
October 08, 2018

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*** ****** ***. ** *****: 419-***-****(Cell)

Valdese, NC 28690 E-mail:

Summary of Experience

An accomplished Senior Quality Engineer with extensive and diverse technical experience in the automotive truck industry. Managed new product launches and implementation of Advanced Product Quality Planning (APQP) to ensure customer expectation are met. Expertise in implementation of six sigma and lean principles, training and mentoring six sigma green belt candidates. Dedicated leader who builds multidi-sciplined teams and effectively utilizes resources to maximize project success and establish metrics to ensure compliance. Managed implementation and monitoring of ISO/IATF16949 audit program and coordinated third party audits. Core competencies include:

Customer Relations Management

Project Management

Advanced Product Quality Planning (APQP)

Measurement System Analysis (MSA)

Failure Mode Effect Analysis (FMEA)

Statistical Process Control (SPC)


Meritor (July 2008 – March 2018)

Senior Quality Engineer / Six Sigma Black Belt

Ensured product quality exceeds customer expectation, addressed customer concerns, root cause analysis, corrective and preventative action implementation (8D).

Managed APQP activity for new product launches, customer and supplier PPAP submission and approval.

Member of launch team that received Chairman’s Quality Award for launching air disc brakes with No Fault Forward hence achieving zero defects goal.

Developed and updated process Failure Mode Effect Analysis (FMEA), control plan, production set-ups, rework instructions and quality standards. Supported continuous improvement of standard work for Brake assembly and Axle assembly.

Improved Internal First Time Yield and Customer Concerns by 35% in first six month with Meritor Inc.

Developed and implemented assessment program for corporate suppliers and supplier PPAP approvals.

Provided Six Sigma Green Belt and Yellow Belt training, mentored and coached green belt candidates through their project completion and certification.

Hella Lighting Corporation (January 2007 – June 2008)

Quality Process Method Engineer

Instituted and implemented Six Sigma Program at Hella Lighting Corporation

Identified and completed three Six Sigma Black Belt projects. The project dealt with scrap reduction, thermal plastic injection molding process optimization and assembly process improvement. The total saving from these projects was $500K.

Provided Green Belt training, mentored and coached green belt candidates through their project completion and certification process. Annual saving from green belt project was $300K

Johnson Controls Inc. (July 2001 – December 2006)

Six Sigma Black Belt / Lean Implementer

Identified and completed twelve Six Sigma Black Belt projects and ten Lean manufacturing projects. The total saving from these projects have been 2.5 million dollars.

All Six Sigma Black Belt projects dealt with reducing process variation hence reducing manufacturing cost.

The focus of Lean manufacturing project implementation of value stream map and assembly line re-balance reduction of freight through trailer load optimization.

Selected cross-functional teams to work on above projects and provided basic Six Sigma, Lean Manufacturing and Kaizen training.

SPX Corporation, Robinair Division (January 1999 – May 2001)

Advanced Manufacturing Engineer

Increased plant labor efficiency by 20 percent through improvement of process flow and introduction of power assisted tools and equipment

As the leader of plant health & safety coordinating team, led the effort to reduce worker injuries through job analysis, accident investigation and implementation of ergonomic tools

Planed manufacturing process, designed assembly tools and equipment to support operations

Identified and resolved new product lunch issues through pilot and per-production build programs

Pakistan Automobile Corporation (July 1993- December 1998)

Diesel Engine Assembly Plant (Start-up)

Senior Quality Engineer

Planned, initiated and controlled the manufacturing activities of the plant in accordance with the prescribed policies and procedures established by the company for quality assurance and manufacturing

Developed proposals and conducted feasibility study for arrangement of additional plant machinery and equipment for objective of progressive manufacturing

Provided provision for special controls, processes, tests, gauges and skills required to ensure product quality

Developed and implemented assessment program for corporate vendors

Truck Assembly Plant (Start-up)

Supervisor, Quality Assurance

Developed quality assurance and plant operating systems and procedures for vehicle assembly plant in accordance with ISO 9000 standards

Trained quality assurance and production personnel to implement systems and conducted quality audits to assess compliance with operating procedures

Allison Transmission, Division of General Motors (September 1981- June 1993)

Project Engineer

Initiated product design changes to improve product quality and durability

Ensured implementation of design changes through prototype model building and testing programs

Evaluated test results utilizing computer assisted statistical techniques

Recommended resolution of manufacturing, assembly and testing problems

Supervised product reliability laboratory activities, guided technicians to carry out daily tasks

Identified and investigated the causes of manufacturing, assembly and design related problems and assisted in solution & corrective actions and verification

Interfaced with United States Defense Agencies to ensure compliance with Military Standards


Bachelor of Science, Mechanical Engineering, – Tri-State University, Angola, Indiana, USA

Bachelor of Science, Education, – University of Punjab, Pakistan

Bachelor of Science, Physics & Mathematics, – University of Punjab, Pakistan

Certification and training

Certification Six Sigma Black Belt, MODAPTS, ISO/IATF16949 & ISO14001 Internal Auditor

Technical Training Lean Implementer, TQM

Computer Skills Microsoft Word, Excel, PowerPoint, Statistical Software Minitab

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