Quality Engineer
Resume:
Resume of Contact Details:
SURENDRA WANKHEDE **616 Greystone drive
Sterling Heights, MI-48313
Ph.no.586-***-****
Cell: 734-***-****/
Email: ************@*****.***
OBJECTIVE:
Pursue a challenging career position in the field of Supplier Quality
Engineering Management in an esteemed organization using creativity,
experience and sound education.
SUMMARY:
• Over Sixteen years of experience in Quality, Engineering and SCM focusing on
Quality, Operations, Designing, Manufacturing, Cost Reduction, Testing,
Continuous improvement in Aerospace and Automotive field
• Managed and trained Engineers/ Technical staff to perform various quality
functions
• As Manager in Suzuki Motors managed 11 Engineers and 175 technical staff.
• Audited suppliers for QSB plus – Quality system basics plus and Process specific
Audits
• Have thorough knowledge of calibration, metrology tools and lab equipment’s
• Have excellent written and verbal communication skills.
• Have strong analytical, organizational, and time management skills
• Followed and ensured compliance with customer requirements, quality policy,
company standards and regulatory requirements
• Tracked, measured, and communicated standard metrics for quality performance
• Managed Quality initiatives working with cross-functional team to ensure timely
execution without any issues
• Planed, prioritized and managed multiple projects in a technical and business
environment
• Designed, developed and managed various projects in Aerospace industries like
IDG and A6SRA test Equipment from Design, Manufacturing, Assembly,
Inspection, Testing and BOM
• Managed inspection and quality control operations and personnel for incoming
materials, in-process assemblies, and finish goods to ensure compliance with
customer SOR
• Employed and monitored the standardization of best practices to ensure quality
products
• Worked with internal teams to develop and implement integrated content required
to drive growth and maximize customer value
• Planned and designed Drive base for Fuel control Test stand
• Planned and designed Jigs and Fixtures for Testing various IDG
• Worked with supplier to develop FMEA, Control plan, Work instruction, Critical
part characteristics, Develop Verification station, Frequency of Inspection, RPN
• Used effectively FMEA, DVP&R, DFMEA, PPAP, APQP, GD&T, SPC, JIT,
TPM, TQM, PPC, KAIZEN, POKAYOKE, QS9000, ISO9000, VA/VE, Robust
Design and Taguchi method, LEAN Manufacturing, Six Sigma, 5S,MRP, ERP,
etc.
• Investigated and analyzed internal quality issues, recommended solutions and
ensured corrective actions implemented to reduce warranty and customer
complaints
• Developed PFMEA and control plans for current and new model
• Used creative thinking for the analysis of data and the identification of new
opportunities
• Responded to customer quality issues and developed (PCPA) quality assurance
plans through analysis, corrective and preventative measures, establishing critical
limits and monitoring procedures and sometime field actions
• Reduced quality concerns both dimensional and appearance through early
intervention with design, ensured proper quality control methods, including
developing gauges, check points, boundary samples, and gate reviews – APQP
• Reviewed inspection data to conform acceptability of the product and processes.
Work closely with manufacturing operation team to eliminate defective
conditions. Controlled/documented defective material, Quarantine for analysis
and maintained database, and distributed reports as required by leadership
• Worked with suppliers to root cause the warranty of the parts and conducted
warranty workshops
• Managed returned material system and processes to ensure customer complaint
receive accurate assessment to resolve quality/warranty issues
• Worked with supplier for developing and monitoring quality parts from Math
data, APQP, Gate reviews, PPAP and PTR at plants to confirm part quality on
vehicles
• Worked with Engineering to validate new products for production readiness
through careful and thorough auditing of product and process documentation, also
recommended change if needed to ensure product quality
• Continuously evaluated product and process data. Based on data implemented
improvements to product and process specifications, quality inspections and
quality assurance procedures
• Experienced in test planning, developing test specifications and procedures based
on input from DVP&R
• Managed projects for various components e.g. Pumps, Columns, Gear, Wheel,
Glove box, etc. from Sourcing thru manufacturing, testing and quality approval
• Managed and improved vendor/supplier relationships by establishing and
maintaining quality requirements
• Trained and supervised Engineers and technical staff in carrying out tests, checks
and inspection
• Worked with supplier to improve quality capability by balancing vehicle structure
standardization and part structure optimization
• Used GM valve system (part of gate reviews) for part development from
resourcing, tool kick-off, tool build, first off, CMM, PPV, NS, S and PPAP if
issues countermeasures taken working with suppliers and Engineers
• Managed crisis to protect plant production in crisis situation like Quality issues,
chapter 11, supply chain issues, capacity issues, labor issues, etc.
• Experience in purchasing operations in GM and BTAB (Business transfer
approval board), Managed various business moves for cost reduction, capacity
management, quality issues, labor contract issues, etc.
• Experience with handling various castings for Cylinder block, Cylinder head,
Transmission case and Cam shaft while working with Suzuki Motors
• Worked on Chassis, interior, exterior parts like complete steering system parts,
seals, pumps, gears, steering columns, Plastic parts like glove box, seal plates,
center columns, wheels, wheel finish, Chrome plating, and cladding
• Experience with forging for Crank shaft in Suzuki Motors
• Experience with Stamping and Body in White, SMED, Transfer-press and
Progressive and compound dies while working with Suzuki.
• Experience with plastic injection molding parts while working with NYX, Inc.
• Designed and developed various Jigs and Fixtures for Flatness testing of
Transmission case, Gun drilling operation fool proofing in Crank, Shifter shaft
location positions checking fixtures, etc.
• Worked in Dynamometer Lab for Engine and Transmission Testing for Acoustic,
Vibration, Bearing studies, Efficiency, Emission
• Produced plans, reports, specifications, instructions, Engineering Change Notices
(ECN) and Engineering Change Request (ECR)
• Developed Vendors for manufacturing various automotive and aircraft
components
• Software skills: Auto-CAD, MS-Office, MS-Windows, Lotus-notes, C and
Prolog.
EXPERIENCE DETAILS:
Dec 2012 to Present
Company: General Motors
GPSC – Sr. Supplier Quality Engineer – Shock / Struts and Global CT Lead
1. Managing Shock and Struts - PPAP
2. DEEP DIVE and program management
3. Warranty and Quality issues
4. Valve system (Gate reviews)
5. 5 phases and Red “X”
6. APQP – design thru production
7. Project management
8. Field / Recall Actions
July 2012 to Dec 2012
Company: General Motors
GPSC - Sr. Engineer – Tactical Operations
1. Supply chain Management – Material availability and plant protection
2. Crisis Management – Supply chain issues
3. Vendor development and Solving Quality issues
4. Tool Move management
5. Providing manufacturing solutions to Supplier and solving quality
problems
6. Inventory and bank management for financially troubled suppliers
Dec 2010 – July 2012
Company: General Motors
GPSC - Supplier Quality Engineer – Steering Systems and Global CT Lead
1. Managing Steering systems- PPAP
2. DEEP DIVE and Program management
3. Warranty and Quality issues
4. Managed EPS, HPS, I-Shaft, etc.
5. Valve system (Gate reviews)
6. 5 phases and Red”X”
7. APQP and Project management
8. Field / Recall Actions
April 2005 – Dec. 2010
Manufacturing Engineer, Inprax Performance Resources Inc. (Aerotek), Madison
Heights, MI.
(On Project at General Motors)
1. Supply chain Management
2. Crisis Management
3. Vendor development and Solving Quality issues.
4. Tool Move management.
5. Providing manufacturing solutions to Supplier and solving quality problems.
6. Inventory and bank management for financially troubled suppliers.
7. Managing labor – contract issues
8. Managing and prioritizing issues, parts during Chapter 11 situation (suppliers).
9. Used VA/VE and man/ material management techniques for cost reduction
10. Used DSS to manage crisis mode
11. Managed Emergency tool move to protect plants.
12. Managed logistics in emergency (Supply chain management).
13. Function as liaison between purchasing, engineering, manufacturing and supplier
to resolve quality issues
June 2004 – April 2005
Manufacturing Engineer, Easi Inc., Madison Height, MI.
(On Project at General Motors)
1. Supply chain Management
2. Crisis Management
3. Vendor development and Solving Quality issues.
4. Tool Move management.
Feb 2004 - May 2004
Manufacturing/Project Engineer, NYX Inc. Shreveport, LA.
(NYX is in the field of Injection Molding Automotive parts for GM and Nissan)
1. Planned and Designed fixtures for various plastic parts such as Garnish, Glove
box, C-pillar, Sill plate, etc. ( Used Auto CAD )
2. Testing the fixture for various problem detection and fool proofing (Poke-Yoke).
3. PLC programming as per required fool proofing implementation.
4. Cell layout designed for line balancing and improving productivity.
5. Designed and developed conveyors for parts flow.
6. Involved in the improvement for GM parts and solving PRR.
7. Worked on A-B-C comparison for PPAP approval.
8. Developed standards and method for Inventory Regrind management.
9. Developed standards for Inventory management in order to reduce cost of
Expendables used for packing materials.
10. Developed methods for Inspection for rejecting the parts.
11. Robots Arm developed for holding parts and spruce.
12. Work measurement and Industrial Engineering.
March 2002- Jan. 2004
Project Engineer, Testek Inc., Livonia, MI
(Testek is in the field of Aerospace and Automotive Test Equipment building.)
1. Planned and designed Drive Base for Fuel Control Test Stand.
2. Planned and Designed jigs and fixtures for various tests stand for testing IDG
(Integrated Drive Generators) (Various Mounting Interfaces has been developed
for IDG like 767 IDG, 747 IDG, 737 IDG, 727 IDG, A340, A330, A320, A310,
etc.) The cost of is reduced by 75% to the original cost.
3. Made bill of material, which include the source of purchase, the cost of item,
quantity required per test stand.
4. Designed and got manufactured Metal components, Sheet metal components.
5. Inspected complete Test stand for intended use, Tryouts and checkouts, Made
manuals and calibration reports
6. Planned, developed and build test set-ups and evaluate results.
7. Investigated mechanical/electrical operational difficulties on products and / or
components and recommend corrective action.
8. Have thorough knowledge of complex mechanical and / or electrical concepts.
9. Have knowledge of engineering drawings Ability to read complex engineering
drawings.
10. Good oral and written communication skills and interpersonal skills.
11. Conducted development and validation testing according to written methods and
standards.
12. Developed new test methods.
13. Troubleshoots problems while testing is underway.
14. Collected and analyzed data from testing.
15. Prepared formal written test report at test conclusion.
16. Looked for Lab safety and 5S.
17. Directed to operators for test fixture build, repair, and modification.
18. Implemented ways of improving test cost and timing.
19. Experienced in electromechanical test areas and Test equipment Design.
20. Strong Microsoft Office skills.
21. Experienced in programmable logic controllers (PLCs).
22. Experienced in laboratory instrument calibration and/or maintenance desirable.
23. Believes in Testing in Time for good decisions.
24. Ability to work in a team and Team building.
25. Physically capable of lifting up to 70 pounds.
April 1998- March 2002
Asst. Manager, Maruti Udyog Limited (Suzuki Motor Corporation), India
(Maruti is in the field of manufacturing automotive 4-Wheelers. Have market share
of 65% in India.)
1. Designed & developed components like air cleaner, air cleaner elements, sheet
metal components, and metal components. The alternative material for fuel filters
are developed reduced cost by 60% of the original cost.
2. Developing vendors, improving vendor’s process to reduce costs.
3. Applied and used FMEA, DVP&R, DFMEA, APQP, GD&T, KAIZEN,
POKAYOKE, QS9000, ISO9000, VA/VE, 5S, Robust Design, etc.
4. Implemented and monitored advance quality planning for selected future product
suppliers
5. Assured supplier understanding of product and submission requirements and
approved supplier quality plans
6. Reviewed and certified supplier manufacturing processes and quality systems
7. Conducted technical meetings to support start up activities.
8. Performed root cause analysis for supplier quality problems and coordinate /
implement effective solutions timely.
9. Capable to determine part critical characteristics for control
10. Have capability to organize, plan and exercise independent judgment
11. Worked in Dynamometer Lab. for Engine and Transmission Testing such as
Acoustic, Bearing studies, Durability, Efficiency, Emission.
12. I have done crank dynamic balancing on NAGAHAMA SCHENK machine.
13. Jigs and fixture designed and developed for measuring flatness of Transmission
case to avoid leakage problem. Also jigs are developed to check the locations of
the dowel holes with respect to the shifter shaft holes, which is very critical in
Manual Transmission.
14. Used effectively FMEA, PPAP, GD&T, SPC, CPK, JIT, TPM, TQM, PPC,
KAIZEN, POKAYOKE, QS9000, ISO9000, VA/VE, Robust Design and Taguchi
method, LEAN Manufacturing, Six Sigma, 5S,MRP, ERP, etc.
15. Fixture developed to fool proofs the Gun drilling operation in Crank for Bearing
and pins.
16. Various design changes done to reduce cost and for ease of manufacture.
17. Participated in continuous improvement activities like KAIZEN to analyze current
procedures to match breakthrough goals.
18. Experience in an electro/mechanical assembly and test environment.
19. Produced plans, reports, specifications, instructions, Engineering Change Notices
(ECN) and Engineering Change Request (ECR).
20. Exposure in stamping for Automotive Industry.
21. Familiar with ASME, ISO, ANSI standards.
July 1997- Feb.1998
Management Trainee, Neco Schubert & Salzer Limited, India.
1. Designed and developed of jigs and fixtures for various cylinder head, cylinder
block, and transmission case for tractor.
2. Line balanced to improve the Productivity of the CNC machines so that the cost
per part is reduced by 30%.
EDUCATION:
• Master of Technology in Industrial Engineering, Nagpur University, India, 1997
• Bachelor of Engineering in Production Engineering, Aurangabad University,
India, 1995.
Training:
1. AOTS training in JAPAN for six months in the area of Suzuki Production systems,
Production management, Inventory Management, Quality Control Techniques,
Application Engineering, Line Balancing, Value Engineering Techniques, PLC
and CNC Programming, CNC Grinding Machines Operation and Setting.
2. At Vickers, India in the area of Basic Hydraulics used for any hydraulic circuits.
Languages known: 1.English 2.Japanese 3.Hindi 4.Marathi
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