Manager Quality
Resume:
VIJAY GHAI
*****, ****** ****, ******* **, 94539
*********@*****.***
LEAN/TPM/ QUALITY /MANUFACTURING
15+ years of executive and leadership experience, senior management position with ABB, Eaton-Shriram
joint venture. MBA, BS degree; Implementation experience of Lean, Toyota Production System, ABB-Gate
Model, Total Productive Maintenance and Eaton Global Footprint Transfer
Delivered > $20M incremental margins through Continuous Improvement/Lean/TPM initiatives through
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implementation of best practice programs in assigned manufacturing and distribution sites.
Key member for training and deployment of Lean Program globally - delivered 5 waves of Lean
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manufacturing training and conducted multiple Kaizen events. Practiced Lean, Six Sigma (DMAIC and
DFSS), Theory of Constraints, Hoshin Planning.
Lead teams to deploy Lean Methodology/TPM, Business Operations, Process Improvement (Efficiency
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and Productivity gains). Hands-on experience in operational excellence tools viz. TPS, TPM and Value
Stream Mapping (VSM).
Key strengths include:
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o Process Management & Strategy Development • Metrics, Dashboards, Balanced Scorecards
o Process Improvement (DMAIC Methodology/A3/TPM)
o Lean & Kaizen Methodologies- Training & Mentoring
Leading the Quality function with focus on Manufacturing processes, Quality planning initiatives,
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QMS, EMS, TS-16949, etc. Complete planning of New Product Development comprising of PPAP,
APQP, FMEA and Product Testing.
US Permanent Resident
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WORK EXPERIENCE:
Flextronics Ltd, Mar ’10 – Present,
Flextronics (www.flextronics.com) is a leading Electronics Manufacturing Services (EMS) provider focused
on delivering complete design, engineering and manufacturing services to automotive, computing,
consumer, industrial, infrastructure, medical and mobile OEMs.
Quality & Business Excellence Manager
Principle Accountabilities/Duties:
• Define training programs for the QA Engineering area in order to detect, solve and prevent
problems on the production processes
• Establish continuous improvement programs, focusing on clients requirements
• Define quality goals for all manufacturing processes for Soft Tool Metal Fabrication, Metal
Fabrication, Laser cutting, Punching, Forming, Assembly and Integration
• Responsible for Process Engineering/Quality Processes for Soft Tool Metal Fabrication,
Welding, Metal Fabrication, Laser cutting, Punching, Forming, Assembly and Integration.
• Responsible for ISO-9001 & ISO- 14001 Certifications
• Used Lean concepts such as leveling workload, “pull” systems, visual controls and
continuous flow to optimize the NPI- Processing Department. Processing finish time was
improved by 45%, while overtime was reduced by 25% resulting in an annual savings of
$130,000.
• Interface with customers on technical/quality issues and improvement initiatives.
• TPM intiative - establishing programs & implementing Focused improvement process and
activites
• Lean Manufacturing - Leading Kaizen events, leading & delivering continuous improvement
projects, leading & teaching self-directed work teams, Strong problem solving abilities,
focused on root cause analysis utilizing DMAIC process.
• M.S. project experience.
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HCL INFOSYSTEMS LTD, Sep’09 – March’10,
HCL Info systems (www.hclinfosystems.com) are premier information enabling company. HCL Info
systems offers value-added services in key areas such as system integration, networking consultancy and
a wide range of support services.
Corporate Planning and Quality Manager
Key Tasks:
• To develop and manage North America region in providing products, solutions and related
services, which include PCs, Servers, Imaging, Voice & video solutions, Networking
Products, TV and FM Broadcasting solutions, Communication solutions, System
Integration, ICT education & training, Digital lifestyle Solutions and Peripherals.
ABB Ltd, Aug ’08 – Sep’09,
ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry
customers to improve performance while lowering environmental impact. The ABB Group of companies
operates in around 100 countries and employs about 120,000 people.
Operations Excellence & Lean Manager
As Operations Excellence :The main focus in the job is to develop and implement
Lean/TPM/Operation excellence modules to create world-class quality and operational
excellence solutions for all ABB business operations together with the businesses and spreading
the knowledge of best practices within the group.
Key Tasks:
• Executed assessments and pre-studies for operations improvement in
transformer/Automation Products/Electric Motors/Sub-Station Automation Manufacturing
plant.
• Conducted trainings, workshops and facilitation inside and outside ABB GROUP.
Key Responsibilities:
• Lead the Promotion Campaign for Lean/ TPS in ABB factories. Participate in defining and
executing the factory /Lean/ TPS master plan. Assessment of the implementation progress
in the factory
• Coordinate Quality/Lean/ TPS trainings at all levels
Accomplished this by working with the Lean Steering Committee as well as each site’s Lean
Coordinator, Executive Committee. Promoted and supported cross-fertilization of ideas,
knowledge, standards and improvements
• Implemented solutions to improve finished goods inventory turns, Work-in-progress
inventory turns, Manufacturing cycle time, On-time delivery rate, Customer lead time,
Supplier Quality/On-time Delivery, Procurement to Cash/Order to Cash Cycle.
• Achieved immediate performance objectives for Operations. Implemented lean
manufacturing and focused on manufacturing excellence and profitability. Key results:
o Initiated training and development on Lean Manufacturing Tools &
Techniques.
o Reduced scrap 50% ($1.3 million).
o Improved first time throughput 15%.
o Reduced Work In Process 58% ($800,000).
o Reduced Dock-to-Dock times by 60%.
o Improved key Suppliers delivery/quality rate by 30%.
SHRIRAM PISTONS AND RINGS LTD, Oct’ 93-August’08,
Shriram Pistons and Rings, Ltd. is one of the leading developer, manufacturer, and supplier of pistons,
piston rings, pins, and engine valves for OEMs in India and internationally. The company with over 1000
employees and annual sales volume of US$200+ Million .
Business Unit Head & Operation Excellence Manager Oct’ 01-August’08,
Key Responsibilities:
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Performed a vital role in setting up a green field Auto Component Manufacturing Project for
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the company in collaboration with US FORTUNE 500 Auto Component Manufacturer .
Successfully coordinated projects like Total Productive Maintenance (TOYOTA
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PRODUCTION SYSTEM) Under Guidance from Japan Institute of Productive Maintenance
(JIPM), Japan and Lean Manufacturing initiatives along with training at Toyota Motor
Corporation Toyota Aichi City, Japan.
To improve Operation excellence parameters by deployment of Lean Methodology/TPM.
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Implement operational excellence tools viz. TPS, TPM and Value Stream Mapping (VSM).
Conducted Quarterly APQP Reviews with Supplier Senior Management and tracked
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Corrective Actions.
Accomplishments:
• Responsible to drive the /Lean/TPM implementation by supporting the Plant management.
• Lead the Promotion Campaign for Lean/ TPM in the factory
• Coach the pillar leaders and members
• Participate in defining and executing the factory Lean/ TPM master plan.
• Coordinate Quality/Lean/TOYOTA PRODUCTION SYSTEM trainings at all levels.
• Leading the Quality function with focus on Manufacturing processes, Quality planning
initiatives, QMS, EMS, TS-16949, etc. Complete planning of New Product Development
comprising of PPAP, APQP, FMEA and Product Testing.
SHRIRAM PRECISION Engineering Industries, Oct’93-Oct’01,
Assistant Manager, Operations
Key responsibilities:
• Handled entire gamut of operation in project launch of I.C. Engine Value Manufacturing
Production Unit.
Lead team of Production to manage day to day shop floor activities for,check the process,
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quality, in time delivery, man-hour booking in SAP ERP system.
ACADEMIC CREDENTIALS:
1997 MBA (Project & Operations), Institute of Management & Technology (IMT), India
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1989-93 BS in Mechanical Engineering, Regional Engineering College, Karnataka, India
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CERTIIFCATIONS:
Certified in Production and Inventory Management(CPIM) – APICS Association for
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Operations Management, USA
Lean Manufacturing(TPS) –AOTS, JAPAN in Collaboration with TOYOTA MOTOR
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Corporation
Theory of Constraint Techniques(TOC) –Trainer – ABB, ZURICH, Switzerland
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