Quality Engineer Manager

VARATHAN THURAISINKAM

**** ******* **** ** *****: 734-***-****

Bloomfield Hills, Michigan 48302 Email: adeldn@r.postjobfree.com

CAREER SUMMARY

Senior Quality professional with diversified and progressive experience in Quality Assurance, Product Development, Program Management, and Manufacturing in the Automotive, Medical device, Aerospace / Defense, plastics, and consumer goods industries.

Experienced in processes such as metal stamping, hot stamping, welding, machining, plastic injection molding, leather manufacturing, cold heading, cold and warm forming, electrical / electronic, chemical, and assembly of Chassis, Engine, Driveline, and Transmission components.

Worked with internally, and externally with Customers, and Suppliers on Continuous improvement projects using Problem Solving skills, Six Sigma tools, Lean Manufacturing, and World Class Manufacturing.

In Global sourcing, worked with cross-functional Team including Product Development, Buyer, Regulatory, Marketing, Production, etc. to launch programs in North America, Canada, China, Mexico, Poland, Italy, and Korea.

Managed Six (6) Plants” Suppliers (Plants in US, Canada, Mexico, Korea, and China).

Managed Quality Teams including Quality Supervisors, Quality Engineers, Quality Technicians, and CMM Technicians up to 30 people.

Upgraded Quality personal through development (Training, Mentoring, & Coaching) and recruitment.

Implemented ISO 9001 & TS-16949 Quality Systems, and ISO-9001(2015). / IATF -16949 Quality Systems.

Managed Customers, Suppliers, and seven Manufacturing Plants in Quality, Delivery, and Warranty.

Implemented KPIs to Manufacturing Plants and Suppliers.

Working with Finance Dept. for yearly budget for Quality Department.

Managed multiple Plants in Quality, Launching Programs, and Implementing Quality Systems.

Lead Quality and cross-functional team in achieving GM-Supplier Excellence for year 2018, and 2019.

Lead Quality, and cross-functional team in reducing warranty claims by 45% with Major OEMs.

PROFESSIONAL EXPERIENCE

Iroquois Industries Inc.

Manufacturers of Metal Stampings, and welded Assemblies for Automotive, Appliance, and Consumer Products.

Warren, MI. Nov., 2017 -Present

Corporate Quality Manager

Responsibilities include developing Quality Systems, APQP, Program Launches, and

personel for Eight (8) Manufacturing Plants. And Management representative for IATF-

16949 / ISO-9001Standards. Interface with Customers and Suppliers on launching

programs, Quality issues, and Suppliers on development. Leading cross-functional team in

launching programs with Customers & Suppliers. Working with Manufacturing Plants in

Customer issues and Continuous Improvement projects. Train, Coach, and Mentor team in

Quality techniques at Plants. Works closely with peers to Develop long term strategies that

drive Company to be best in class. Manage audit programs.

Successfully implemented IATF-16949 at eight (8) Manufacturing Plants.

Developed a comprehensive APQP system including roles and responsibilities.

Implemented MRB process at Manufacturing Plants.

Implemented robust process in scrap reduction.

Reduced Customer PPM by 50%.

Reduced Supplier PPM by 60 %.

Reduced Customer Warranty by 50%.

ZF,

Body Control Systems

Livonia, MI. Feb., 2016 –Oct., 2017

Global Automotive Manufacturers of Electronic and Electrical components.

Customer Quality Manager

Responsibilities include maintain and communicate voice of the Customer requirements,

and lead Programs launch at Customer Plants, and Eleven (11) ZF Plants including

Plants in North America, China, Mexico, UK, and Italy, Poland. Primary communication

with Plant Quality Manager, Quality Director, Plant Manager, Program Director,

Engineering Director, Operation Director, and Sales Director. Initiate, and implement

improvement programs to ensure the Customer requirements and Expectations are

communicated to all ZF Plants including training tools, techniques, and manufacturing

methods. Lead Schedule, and Customer Scorecard/ issues reviews. Ensure adequate

planning, and performance of customer management processes. Assist sites in negotiating

PPM/ NCTs. Supervising five (5) Tech Reps.at Customer Plants.

Launch Programs with Customers at Plants in Mexico, Poland, China, Italy, and North America.

Implemented KPIs to improve Customer satisfaction and Program launches.

CHRYSLER GROUP LLC.

Auburn Hills, MI Aug., 2011 – Feb., 2016

Global Automotive Manufacturer of Jeep, Dodge, and Chrysler vehicles.

AQP / PSO Manager/ Supplier Quality Manager / Quality Manager

Responsibilities include organize and manage advanced Quality planning (AQP) & Process

Sign –Off (PSO) activities for all new and modified stampings. Develop timing and provide

activity support for key AQP and PSO deliverables (i.e. AQP meetings, Quality document

development, Supplier Readiness Evaluation, Pre-PSO meetings, PSO On-Site, and

PPAP). Organize & manage AQP/PSO activities on key purchased components /

stampings. Function as primary stamping Plant contact and Program Manager for Supplier

Quality on all new programs Implementing World Class Manufacturing (WCM)

methodological in launching process. Working with Assembly Plants in Quality, Delivery,

and Warranty.

Implemented, and trained Processes / Procedures to meet PSO /APQ requirements at

the Plant.

Launched stamping (under body, A, B – Surface body, etc.), and Assembly parts for

Chrysler Assembly Plants.

Launched programs with Suppliers for ten (10) purchased stampings/ components.

Developed Suppliers to meet Chrysler requirements.

Launched three vehicle Programs successfully.

Managing 10 Quality Engineers, and 7 Quality Technicians, and 1 Lab Technician.

Maintains Quality assurance staff by recruiting, selecting, orienting, and training

employees.

Maintains Quality assurance staff job results by coaching, counseling, and disciplining employees; planning, monitoring, and appraising job results.

Completes quality assurance operational requirements by scheduling and assigning employees; following up on work results.

Prepares product and process quality reports by collecting, analyzing, and summarizing information and trends.

Implemented training for Quality Systems, and Documents.

Implemented, and managed continuous improvement Projects with WCM, Six Sigma, and Lean Tools.

Managed Program Launch, and Quality Dept. fiscal budgets, Scheduling expenditures

Managed five Assembly Plant Tech Reps.

Establishes raw material standards by studying manufacturing and engineering requirements; conferring and negotiating with suppliers; devising testing methods and procedures.

EAGLE BEND MANUFACTURING INC., COSMA BODY SYSTEMS, MAGNA INTERNATIONAL, Clinton, TN Dec., 2009 – July, 2011

Tier 1 Supplier of Body, and Chassis Systems to Global Automotive Manufacturers.

Quality Supervisor/ Senior Quality Engineer

Responsibilities included developing quality systems, performing process capability studies,

Control plans, APQP, PFMEA, PPAP submissions, quality training, quality audit, preparing

Process and quality instructions, continuous improvement activities using Six Sigma, and

Lean Manufacturing, dealing with customers and Suppliers on quality issues. Working with

Cross-functional Team on new launches (Customer and Supplier), and Supplier

Management and Development. In charge of Quality Laboratory for testing activities,

Capital equipment procurement and Launch activities. Managed 10 Quality Technicians in

the Welding laboratory.

Launched five major programs with Suppliers.

Launched four new programs with OEMs (FCA, FORD, & GM).

Developed two new Suppliers to TS-16949 Standards.

Implemented several procedures in the Quality Laboratory to meet OEM requirements.

Reduced PPM with Customers by 50% and Suppliers by 30% through Continuous Improvement Projects.

Managed 75 % of Plant’s Customers (FCA, FORD, GM, Nissan, & BMW).

JOHNSON CONTROLS, JCIM, Frenchtown II, Monroe, MI Nov., 2008 – Aug., 2009

Tier 1 Supplier of Interiors to Global Automotive, and Medical device manufacturers.

Quality Engineer / Supplier Quality Engineer

Responsibilities included developing quality systems, performing process capability studies,

Control plans, APQP, PFMEA, PPAP submissions, quality training, quality audit, preparing

Process and quality instructions, continuous improvement, dealing with customers and

Suppliers on quality issues and working on new launches with advanced engineering in

Injection molded products and Poly bond headliners.

Launched two headliner programs in two months.

Managing seven (7) programs, and their Suppliers.

Implemented Supplier Quality Systems and Development Programs.

Launched two successful programs with major Medical Device Industry.

METALDYNE CORPORATION, Plymouth, MI May, 2003-Sept., 2008

Tier 1 Supplier of metal based components to Global Automotive, and Aerospace / Defense manufacturers.

Corporate Supplier Quality Engineer Aug., 2006 –Sept., 2008

Working for Corporate Global Purchasing Group. Responsibilities include managing suppliers for Power train / NVH plants. Involved in supplier selection, risk assessment, Quality System audits, PSO, APQP, PPAP submissions, Program / Product launches at suppliers, quality issues, and Continuous Improvement activities at Suppliers.

Reduced Suppliers’ PPM by 30-40% / year.

Successfully launched Multi - Programs at suppliers for six (6) plants.

Successfully launched programs and managed Suppliers in US, Canada, China, Korea, & Mexico.

Launched two Programs with major Aerospace / Defense industries.

Developed new Suppliers for six (6) plants.

Implemented Supplier Audits and Risk Assessments.

Quality Engineer May, 2003 –Aug., 2006

Responsibilities included developing quality systems, performing process capability studies, control plans, APQP, PFMEA, PPAP submissions, quality training, quality audit, preparing process and quality instructions, continuous improvement, dealing with customers and suppliers on quality issues and working on new launches with advanced engineering in machining, cold and warm forming.

Maintained zero PPM with Honda (Transmission side gear program).

Passed TS-16949 audit for three years.

Reduced internal scrap by 30 % in the Machining and Forming areas.

Implemented and maintained layered process audits for entire plant.

FORD MOTOR COMPANY, National Parts Distribution Center, Livonia, MI

Feb., 2001-April, 2003

Global Automotive Manufacturer of Ford and Lincoln vehicles.

Supplier Technical Assistance / Warranty Engineer

Responsibilities included launching of Warranty Reduction Program at suppliers, and performing as a liaison to interface with suppliers / dealers and Ford management, tear down analysis, serve as a technical expert on evaluation of warranty parts for charging back dealers, interface with Supplier Technical Assistance Engineers on service / production parts' warranty issues, supported Quality Systems ( Q1 / QS9000 / ISO9000 ) effort within PS&L, performed facility reviews at potential new program suppliers, followed-up corrective actions ( 8-D ) with suppliers, and provided technical support to engineering, sales / marketing,& purchasing.

Reduced Warranty cost by 1.0 million every year for two (2) years on Engines / Transmissions by launching Warranty Reduction Program at Suppliers.

Improved Suppliers to FORD Warranty requirements by using Six Sigma tools, and Lean Manufacturing.

Launched Warranty Reduction Programs at 4(Four) Suppliers.

Implemented Technical bulletins / Call centers for Dealers.

Improved Warranty Claims process timeline by half.

JOHNSON CONTROLS, INC., Automotive Systems Group, Lapeer, MI. Sept., 1999- Nov., 2000

Tier 1 Supplier of interior systems (headliners and assemblies) for Global Automotive manufacturers.

Quality Engineer

Responsibilities included developing quality systems, PPAP submissions, performing process capability studies, control plans, PFMEA, quality training, quality audit, preparing process and quality instructions, continuous improvement, dealing with customers and suppliers on quality issues and work on new launches with advanced engineering.

Maintained zero PPM on Toyota program.

Successful launch of two Toyota programs.

Passed QS 9000 audit every six months.

Implemented effective training program for operators to reduce scrap by 30%.

TORAL CAST, Division of TESMA International Inc., Concord, Canada. May, 1996- July, 1999

(Magna International)

Tier 1 Supplier of aluminum die-cast, machining parts and assemblies to Global Automotive, Medical device, Aerospace, and Defense manufacturers.

Quality Engineer

Responsibilities included performing process capability studies, PFMEA, PPAP submissions, process control plans, G R & R studies, APQP, quality training, quality audit, continuous improvement and working with customers and suppliers on quality issues.

Reduced scrap by 50% through problem solving activities, training programs, and using

Design of Experiments (DOE).

EDUCATION / TRAINING

Certified Six Sigma Black Belt (CSSBB), American Society for Quality, WI 2009

Master of Business Administration (MBA), University of Michigan, MI 2006

Certified Quality Engineer (CQE), American Society for Quality, WI 1992

Certificate in Quality Assurance, Ryerson University, Canada 1988

Bachelor of Engineering, B. Eng. (Honors), Mechanical Engineering, ABU, Nigeria 1986

MEMBERSHIPS / AFFILIATIONS

The Engineering Society of Detroit, USA, Member 2007

American Society for Quality, USA, Senior Member 1988-Present

American Society for Quality, Detroit Section Professional Development Committee member

2012 - Present

The American Society of Mechanical Engineers, USA, Member 1988 -Present

The American Society of Mechanical Engineers, Detroit Section Secretary 2016 - 2019

ADDENDUM

ADDITIONAL TRAINING

Total Quality Management / Problem Solving Techniques.

World Class Manufacturing (WCM).

ISO 9001 / IATF-16949 Implementation / Internal Auditor.

Design of Experiments / Geometric Dimensioning & Tolerancing.

AS9100 / ISO 13485.

Co-Ordinate Measuring Machine / Faro-Arm.

Lean Manufacturing / Customer Driven Six-Sigma / Kaizen.

Minitab / Applied Stats (Statistical Soft wares) / Plexus Software.

FMEA, PPAP APQP, & PSO/ SPC / DOE / MSA.

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