XITYZ SAGAR

Mobile: 851******* DOB -**/*/**** E-Mail: adb9rq@r.postjobfree.com

Experience in handling Managerial assignments in Project Management / Lean Management / Quality Assurance & Control with an organisation of repute in Automotive & Electrical products Manufacturing companies of various products like

Plastic components (TAFE ), Cars(TOYOTA), Capacitors (ABB), Shock absorbers(TENNECO), Motors(KIRLOSKARS), Transformers(TBEA) & (Transformer & Rectifier). Career Precise

Over two decades of experience (20 Yrs) in the areas of Project Management, Quality Assurance, Quality Control and QMS Management in Automotive & Electrical product manufacturing companies.

Possesses good knowledge of Project Management (India & Overseas Customers), Vendor Development and Management (India & Overseas), Raw Material Inspection Management, Parts Quality Management, In-Process Quality Management, Safety Management, Kaizen Management, Cost Reduction and VA/VE Activities.

An enterprising leader with proven abilities in leading teams towards the achievement of organisational goals and industry best practices.

Well versed with Project Management, Lean Manufacturing, Lean Organisation Management, Supply Chain Management, Logistics, Advanced Manufacturing Processes & various Manufacturing Strategies

Excellent interpersonal, analytical and troubleshooting skills with ability to synthesize complex information and communicate innovative and practical solutions to difficult problems. Core Competencies

Project / Plant Management

Spearheading activities involving working out

various requirements & monitoring overall

project operations for ensuring timely

completion.

Monitoring the activity at automobile &

electrical project schedule, ensuring cost control within budget, planning for cash flow

requirements, etc.

Team Management

Leading, training, mentoring & monitoring the

performance of team members to ensure

efficiency in process operations and meeting of

individual & group targets.

Creating and sustaining a dynamic environment

that fosters development opportunities and

motivates high performance amongst team

members.

Quality Assurance

Defining & implementing quality standards and

structured processes / quality plans for various

production & inspection activities.

Prioritizing quality assurance responsibilities

based on the integration of new designs and

products into current production schedule.

Monitoring and optimising the manufacturing

processes & troubleshooting problems in

coordination with other departments for new

product development & improving efficiency

Value Analysis / Value Engineering

Focussing on optimisation of parameters,

initiating process improvements for achieving

objectives & productivity targets.

Assessing quality performance in production

areas along with the analysis of departmental

production goals verses quality and cost

objective.

Important Achievements till Date –

1) Implementation of lean principles in all the companies worked till date. 2) Getting Best Operational excellence plant award for ABB capacitor division. 3) Restructuring the QD organisations Teams in Kirloskar Motors, TBEA and Transformer & Rectifier with the best QMS principles implementations.

4) Getting TBEA, ISO certified as an MR by developing QMS from scratch through Training & Development. 5) Reduction of COPQ in all the organisations through various analysis using SQC tools. 6) Domain consultant for all the QMS related software made in TBEA. 7) Got appreciations in all the companies for out of box approaches to solve various quality improvements. 8) Handles various Quality successful projects for MBA / GET batches in various organisations. 9) Being the visiting Judge for State Level “Kaizen” & “QC Circle” competitions conducted by CII, Vadodara. Organisational Experience (Present & Past)

TRANSFORMER & RECTIFIER, AHMEDABAD (DT, Medium V & HV Transformers) DGM/HOD - QA since Sep 2018

TRANSFORMER & RECTIFIER is a Indian manufacturer of all ranges of transformers and other electrical products like tanks, bushing, CT, radiators & switchgears. Roles & Responsibilities

Head for handling QD for 3 plants situated in ODHAV, CHANGODAR & MORAIYA, manufacturing Distribution Transformer, Medium range and HV transformers respectively.

Indirectly Heading Quality for T&R other plants manufacturing Radiator, bushing and Tanks.

Overall developing strategies and systems for improving quality at vendors place, Inprocess and customer’s site.

Development and training to all team members in Quality management principles and SQC.

Planning & execution of vendor development strategy for the new & as well as existing vendor base. Highlights of Achievements in TARIL in the year 2018~20. 1) Major changes done in organisational structure and scope of work of each individual leading to improvement in quality and cost reduction too.

2) Development of the technician on shop floor w.r.t. quality awareness & 5S systems. 3) Running of various projects through analysis of Incoming, Inprocess and customer feedbacks, resulting in various product quality improvements.

TBEAEI, VADODARA (Product – HV Transformers) Senior Manager - QD Since Jan 2014 ~ Aug 2018 Tebian Electric Apparatus (TBEA) is a Chinese manufacturer of power transformers and other electrical equipment and handling various EPC projects. Roles & Responsibilities

Management Representative (MR) for ISO 9001/ ISO 14001 & BS OSHAS 18001 Integrated Management System (IMS) for TBEA, Transformer product & Responsible for MIS reports & analysis.

Consultant for other new manufacturing units of TBEA in Phase II projects for QMS implementation and certification.

Head for implementation of Lean manufacturing concepts, Quality system developments &cost reduction projects.

Handling analysis & closure of customer complaints.

Certified (NABL) internal auditor for handling ISO 17025:2005 for TBEA NABL testing Lab internal audits.

Handling internal training for ISO 9001 for the TBEA team members experienced as well as GETs.

Overall quality systems implementation & improvement in Incoming, in process & final inspection for Quality Department.

Planning & execution of overall strategy for the QD department developments & improvements.

Planning & execution of vendor development strategy for the new & as well as existing vendor base of TBEA.

Supporting vendor assessment of suppliers.

Controlling the (COPQ) cost of poor quality & various cost reduction activities.

Overall responsible for new developments & improvements for single product quality developments. e.g formation of various softwares for Quality Management Systems.

Highlights of Achievements in TBEA in the year 2014~18. 4) Getting TBEA- Single product ISO 9001 certification with zero NC in the final audit. 5) Making of Inprocess Inspection check sheets for reactors & transformer. 6) Visiting Judge for several GUJRAT State level “Kaizen” & QC Circle competition organised by CII- Vadodara. 7) Making several development softwares for effective implementation of QMS. 8) Trained as Certified Internal Auditor for to ISO 14001:2015, BS OSHAS 18001:2007 & ISO 17025:2005. ( NABL) Kirloskar Electric Company, Bangalore (Product – Motors) Senior Manager - QA Sep’09~ Dec 2013 Kirloskar Electric Company Limited is one of the largest electrical product manufacturing companies in India. Kirloskar Electric makes different electrical products like Motors (0.37kW ~6MW), switchgear, Transformers like Oil cooled distribution/Power type, cast resin type (160kVA~100MVA), DG Sets (12.5kVA ~500kVA), AC Generators

(1kVA~20MVA) & Electronic drives.

Role;

Management Representative (MR) for ISO QMS implementation for the KEC, Plant.

Certified Lead auditor for ISO and handling ISO 9000-2008 audit for different Kirloskar plants in INDIA.

Handling special projects for Kirloskar’s owned German company LDW for development of special motors being manufactured for international markets.

Responsible for feasibility study for Joint venture Project of Kirloskar with Hitachi, Japan for motor project.

Handling as a Project manager all special projects of NPCIL, NTPC, ABS, IRS, QAE etc in India.

Handling overall quality Dept. Activities (incoming, in- process and final product) of 2 plants in Bangalore.

Handling new supplier approvals & existing supplier audits & developments for heavy fabrication, sheet metal fabrications, casting & machining of components.

Functioning as Manager for Lean Principle implementation and training trainees on lean principles.

Controlling the cost of poor quality & various cost reduction activities. Highlights;

Successfully completed projects as a Project manager all special projects of NPCIL, NTPC, ABS, IRS, QAE etc in India.

Drastically reduced the Incoming parts rejections by supplier development & reducing process quality rejections from 73% to 11% resulting in reduction of COPQ by 80%.

Development & improvement of supplier’s quality in heavy fabrication in the field of welding, machining, aesthetics & Shaft quality using DP, UT, MPT testing.

Handling the customer witness inspection of shafts, heavy fabrication, sheet metal fabrication, machining, In-process assembly inspections & final dispatch inspection for projects of NPCIL, NTPC, ABS, IRS, QAE etc in India.

Formation & implementation of project management systems for handling esteem critical projects. TENNECO, Hosur, Bangalore(Product – Shock absorbers) Project Manager - R & D Team Apr’08 ~Aug09 Tenneco has grown to become one of the world's leading designers, manufacturers and distributors of emission control and ride control products and systems for the automotive original equipment market and the aftermarket. Tenneco customer base includes Toyota, Nissan, Mahindra, Honda, Tata, Ford, GM etc. Role;

Directing various OE projects for automobile customers like Toyota, Nissan & Volswagon.

Functioning as the Manager for several OE and after market export projects for customers like Ezgo, Club Car, Ferris in US and Finwhale (Russia).

Monitoring cross functional teams of R&D, Planning, Purchase, Maintenance, Quality, Sales and Marketing.

Analyzing and furnishing solution for profitability and loss of project.

Furnishing VA/VE suggestions to meet dept. cost reduction targets. Highlights;

Significantly improved the EBIT for the several projects by giving VA/VE suggestions

Efficiently implemented the project management systems for the overseas project.

Heading the projects of localisation of parts for several projects. Asea Brown Boveri (ABB), Bangalore(Product – Capacitors) Quality & Lean System Manager Jan’05 – Mar’08 ABB India is No.1 multinational company dealing with all types of automation & electrical products Role;

Handling special customer projects like Power Grid etc. from the design stage to installations.

Handling overall quality Dept. Activities (incoming, in-process and final product), ISO audits & implementation.

Functioning as Manager for Lean Principle implementation and monitoring various process improvements with respect to Lean Management in house & at supplier place.

Controlling the cost of poor quality & various cost reduction activities.

Window person for customer complaint collection, analysis and resolution.

Formation & heading the quality-training centre for new trainees. Highlights;

Effectively boosted the operations of the capacitor plant in ABB, Bangalore to get the operational excellence award in India within a span of 1.3 Year.

Successfully gave a facelift to overall quality of product FPY from 65% TO 91 % acceptable product to customer in a span of 1 year by implementing lean principles & solving various problems in-house & at supplier end.

Handled special projects of Power Grid India from procurement stage to the installation of substations.

Drastically reduced the customer complaints by forming special task force for analysis and solution. Toyota Kirloskar Motors Ltd. (TKML), Bangalore( Cars) Team Leader Feb’99 - Dec’04 TKML is a joint venture between Toyota Motor Corporation, Japan the world's second largest automobile giant & Kirloskar group of companies manufacturing world-class passenger utility vehicles (Qualis) & luxury vehicles (Corolla), INNOVA& VIVA with sophisticated world class manufacturing facility in Bangalore. Role:-

Monitoring In-Process Audit and Investigation Department, Parts Receiving Dept., Material Inspection Lab & Toyota Training Centre from 1999 to 2004 as a Team Leader.

Overseeing local, CKD, MSP & service parts inspection Dept. using TS16949:2002 & Toyota Supplier Quality Assurance Manual.

Enforcing various new projects using APQP, PPAP, FMEA, POKE YOKE tools.

Developing vendors in the quality management systems & PPM control.

Scrutinizing different vendors for Quality development and kaizen implementation.

Directing the QC circle activities for problem solving using various QC tools.

Executing Kaizens (continuous improvement), 5’S’ concepts and VA/VE activities.

Conducting shipping quality check of final vehicle & vehicle functional process evaluation.

Investigating the defects & solving various quality problems using QC tools. Highlights

Holds the distinction of having specialized technical training in Toyota Motor Corporation, Japan in: o Training on Toyota Production System

o Training on safety & QC Circle for Solving Problem. o Training in Kaizen Activities.

o Pre-Delivery Inspection Training on Fitment & Aesthetic Inspection of Vehicle. o On Job Training on Process Audit of Assembly Line & Welding Line. o Defect Investigation & Troubleshooting in Vehicle.

Significantly set up the quality inspection department in Toyota Kirloskar Motor with respect to the Lean Management Principles.

Successfully handled several QC circle activities in Toyota.

Accredited as the Certified Trainer for the Toyota Training Center for lean and quality principles. Educational Credentials

(M Tech.) M.Sc. (Engg.) in Engineering & Manufacturing Management from Coventry University [U.K.] in association with M. S. Ramaiah School of Advance Studies, Bangalore, Karnataka in 2003.( First class) Professional Trainings

Trained in lean management principles in TOYOTA MOTOR CORPORATION, JAPAN for 3 months.

QC circle, Kaizen & 5’S’ training in Toyota Kirloskar Motor, Bangalore.

Trained in Modules on TQM, Lean Management, Six Sigma, etc. from CII – Bangalore.

Certified Lead Auditor for ISO 9001-2015.

Certified Inter Auditor for ISO/IEC 17025-2005. (NABL certification for Lab.)/ ISO 14001 & BS OSHAS 18001.

Short term awareness training in QMS in Hitachi Motors Company in JAPAN for a week.

Getting TBEA INDIA new plant ISO certified through BV single handed with zero NC in a Span of 3 Months. Other Details

Languages (Speak & Understand): English, Hindi, Bengali, Punjabi, Kannada & Japanese (Partially). Family Details

Presently permanently settled in Vadodara (GUJRAT) with 2 Kids & wife. Notice Period

3months & negotiable

Present CTC- Rs. 25 Lakhs per Annum

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