Quality Assurance Project

CAREER OBJECTIVE: Seeking a position where Quality Assurance, Project Management and Engineering experience will add value to operations.

WORK EXPERIENCE:

Main Accomplishments:

**/**** ** */***5 Quality Engineer

STT Technologies, Magna Powertrain, Concord, Ontario, Canada

STT Technologies is a part of Magna Powertrain of the Magna group that manufactures various types of Oil pumps for the automobile industry (GM, Honda, etc.). There are automated assembly and machining lines for the manufacture of the oil pumps. Was on a 6 month contract at STT.

oResolved Supplier related component problems – fallout rate reduced at supplier end from 50% to <1% of vane rings. Rejection rate at 3rd party 100% sort reduced from 5% to 0% of springs. Introduction of conveyorised demagnetization of rotors at supplier brought down the magnetized rotors defect to 0%. Introduction of Master Gage for thickness of gears from 100% inspection to sampling inspection.

oProcess improvements at STT – Rejection due to static flow eliminated by adding O-ring to the clamps to prevent air leakages from taking place. Reduction of failures due to improper torque on pump rotors from 5% to <0.5% by correcting vane ring OD. Process scrap reduction due to nicks, dents on pump, with the introduction of air knife jets for removal of debris.

oCost saving – Reduction of GP12 inspection. Reduction of scrap levels in 1 month. 11% increase in production capacity @ 85% efficiency by reduced throughput time, due to process improvements made. Reduction in customer returns (2 meetings of 1 hour each reduced to 1 meeting of 25 minute for general review only). Nil customer returns in the past 1 month. Contributed to reduction in Cost of Quality.

oCMM measurements all cleaned up and updated.

o2 major PPAP approvals obtained from 2 customers.

oObtained PPQP approvals for PHEV pumps (new product development). Purchase order received for the development of production tools.

04/2012 TO 03/2014 TS / Audit Coordinator

Hoerbiger Finestamping Inc., Waterloo, Ontario, Canada.

Hoerbiger Finestamping Inc., is part of the Hoerbiger group based in Germany/ Switzerland that manufactures Fine Stamped parts for the automobile industry (GM, Ford, Magna, Linamar, etc.).

oHelped in reducing Cost of Quality from 11% of sales to 2% of sales, resulting in cost avoidance. Reduced scrap levels, by introducing 2 pass grinding instead of single pass grinding, thereby saving money for the company.

oSuccessfully completed TS16949 & ISO 9001: 2008 external audit with TUV in July 2012, and obtained recertification for the company. Successfully concluded the TS16949 External Audit by TUV in July~August 2013.

oHelped in the computerization of “CAR system”, “Maintenance systems of downtime, MTBF, MTTR”, “Scrap monitoring system” and “Delivery performance of suppliers”. Integrating Scrap data collection with the ERP work.

oFinalization of Ford labels for Bartender software.

oPreparation of Process flow, Control Plan, PFMEA and Capability analysis for the new products for Exedy project

oSuccessfully completed ISO 14001 External Audit of the company, with TUV, in December 2012, and obtained re-certification for the company.

01/2011 to 01/2012 Project Planner / Scheduler and Project Technical Training Administrator

Comtech, C/O General Motors (GM) of Canada Ltd., St.Catharines, Ontario, Canada.

Comtech is in a contract with General Motors to provide resources to help set up the Powertrain facility for the GF6 (Global Front Wheel drive 6 speed transmission) Transmission plant with a Project Cost of around 300M$, for 3 different model automobiles.

04/2008 to 11/2009 Quality Assurance Manager

Indalco Alloys, A division of Lincoln Electric Company

939 Gana Court, Mississauga, Ontario, Canada

Manufacturer of Aluminum Alloy Welding wire, with customers in China, Australia, Europe, Canada, USA, etc. Welding wire consumable supplied to all major industries including Honda for structural welding.

oIn-charge of all quality related activities and Management Representative on Quality Issues

oResponsible for ensuring ISO 9001: 2000 certification. Cleared 2 audits without any non-conformance.

oPioneered and developed Quality Assurance tracking data (KPI) including: Cost of Quality (COQ), Cost Avoidance (CA), Return on Investment in Quality (ROI) & Process Capability Analyses (SPC), 8D Analyses, Continuous Improvement (Kaizen), Benchmarking of competitors’ products, and reduced scrap generation.

oCOQ reduced from 8% down to 2,5% in 1.5 years. CA of over $800,000 in 2009 and over M$1.00 in 2008.

oLeader of 6 sigma project for quality improvement.

oInitiated and Implemented procurement of Scanning Electron Microscope (SEM) and Smoke Tester, successfully. Negotiated price reductions for SEM.

oSuccessfully obtained CWB, AWS, TUV and Maritime (BV, DNV, ABS, LR, GL) welding certifications for the company, and to ensure product sales worldwide.

oEstablished welding procedures for wires of different diameters and aluminum alloys.

oSuccessfully had Indalco included as an approved vendor with a company (BAE), through accepted welding procedure.

oWas directly involved, along-with purchasing and design engineering, in the new vendor development of plastic spools which were hitherto a cause of problems at customer end.

oHelped reduce defective customer returns substantially.

oSupervised a team of 7 people as the QA Manager.

08/2007 to 04/2008 Project Planner/ Scheduler

Washington Division of URS Corporation,

C/O General Motors Canada Ltd., Oshawa, Ontario, Canada

URS was on contract with General Motors to set up the Flexible Assembly line project for Camaro vehicle.

09/2000 to 08/2007 Quality Assurance Manager

Chalmers Suspensions International Inc, Mississauga, Ontario, Canada

Tier 1 Manufacturer & Design of Truck suspensions for all Truck OEMs in USA, Canada, Australia, etc.

oIn-charge of all quality related activities and associated with the Management Team of Chalmers.

oWas responsible for establishing procedures & systems for in-coming (over 2000 components per week), in-process and final inspection of laser cut and plasma cut formed & bent steel parts, tubes, hardware, steel spun parts, painted, rubber, machined (CNC) & heat treated components, castings and welded assemblies (both Manual & Robotic), threaded products, for the 1st time.

oAdvised / Assisted Engineering and Purchasing department on quality issues. Participated in drawing reviews of Engineering releases (GD&T), especially related to In-Process issues.

oSupported the release of prototypes of new suspensions, tooling, equipment by ensuring that the requirements fixed in the quality plan are fulfilled.

oEnsured that welding procedures and welding data sheets are approved through ‘Canadian Welding Bureau’ per CWB 47.1 standards.

oPerformed new sample submission inspections and provide accurate reports to management, including new suspension design & manufacture.

oIn-charge of quality audit as a Lead Auditor.

oQS9000 Certification: was instrumental in achieving QS9000 certification for Chalmers. Completed QS9000 documentation including FMEA, MSA, PPAP, APQP, for a major line of products made for the 1st time at Chalmers.

oReduction in Cost of Quality (COQ), from $97.82/suspension to $14.81/suspension and saving, since the past 6 years, of several Million $ (>3M$) for Chalmers and the Return on Investment (ROI) on quality of over 11.0.

oHelped eliminate defective customer returns.

oJoined the organization as Project Engineer in September 2000 and rose to the level of Quality Assurance Manager, since April 2003.

oIn charge of Material cost reduction project using the Reverse Auction process that has resulted in material cost reduction of over 5% resulting in annual savings to the company.

04/1984-04/2000 Manager, Projects

Maruti Suzuki India Limited (MSIL), New Delhi, India.

This facility is a joint venture between the Suzuki Motor Corporation, Japan and the Government of India with a turnover of CA$ 3000 million & 0.5 million vehicles/year capacity for 8 different vehicle models and their variants.

04/1980-04/1982 Engineer

Larsen & Toubro, Bombay, India.

One of the largest engineering conglomerate in India manufacturing electrical, mechanical fabricated items, and systems.

oDeveloped process engineering methods & improved productivity for Press, Fabrication, Machine (Die casting machining) and Molding shops.

oDesigned press tools for mechanical presses (stamping shop) and improved productivity of tapping tools.

EDUCATION:

1982-1984 Post Graduate Diploma in Management (MBA)

Indian Institute of Management, Bangalore, India.

Evaluated & Recognized by WES as equivalent to a Master’s degree in Canada

oCourses taken at this internationally recognized school of management included Management Information Systems, Finance, Production and Project Management.

1975-1980 Bachelor of Technology in Mechanical Engineering

Indian Institute of Technology, New Delhi, India.

Evaluated & Recognized by WES as equivalent to a Bachelor’s degree in Canada

oGraduated with honors from this premier engineering school in India, which has worldwide recognition.

ADDITIONAL TRAINING:

oAttended the ISO/ TS16949:2009 Internal Auditor Course by ‘The Business Resource Centre on June 6, 2012 at HFS Inc.

oAttended the ISO 14001: 2004 EMS Internal Auditor training course by ‘The Business Resource Centre on December 3, 2008 at Indalco Alloys.

oAttended Six Sigma Red Belt Training course in 2008 at Lincoln Electric Company.

oAttended the ISO 9001:2000 Internal Auditor Training workshop at Chalmers, Canada, May 2, 2006.

oAttended Welding related training conducted by Hobart at Chalmers, Canada, and obtained very high marks in the test conducted by them, May 12, 2005.

oIn-house training at Chalmers’ (Canada) sister company, on fundamentals of operation of Coordinate Measuring Machine (CMM), 2004.

oAttended the QS9000 Internal Auditor Training Workshop by BRI International Inc. April 3, 2003, at Chalmers.

oCompleted AutoCAD levels 1,2,3 at Sheridan College, Davis Campus, Brampton, Ontario, Canada, September 2001, November 2001 and December 2001.

oYasnac MRC Robot Controller Basic Programming Training, at Chalmers, Canada, November 2001.

oGeneral Management Training, Suzuki Motor Corporation, Japan, May 11, 1987 to May 22, 1987.

COMPUTER SKILLS:

oEmail, arranging net meetings through Lotus Notes, Outlook.

oCustomer based software – Plex (MPT), Covisint – GQTS (GM) and Q1 (Ford)

oSoftware for supplier contact – Supplyweb, DMN.

oIntra company software – ECN.

oMinitab Statistical Process Control software

oNavisWorks 3D software-Freedom.

oAutoCAD

oVisual Manufacturing (ERP software package)

oCADKEY

oPRIMAVERA Project Management Software P3 and P6

oMS-Project 2000 & MS-Project 2007

oMS-Office & Visio

PROFESSIONAL MEMBERSHIPS:

oMember Society of Automobile Engineers (SAE) (in India)

oFull Member, American Society of Quality (ASQ)

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