Quality Manager

Rajesh Yadav **********@*****.*** +91-975*******

Dedicated and enthusiastic professional with 24 years of experience in automobile industry. My professional journey exposed to wide range of profiles like New part development, Supplier Quality assurance, Assembly shop operations, Receipt Quality, Process Quality, Product Quality, Problem solving (Six sigma approach), QMS & HSEEn certification, Manufacturing Engineering, Project management related to Engine Assembly, Truck & Bus Assembly & two wheelers Assembly.

Certified Lean Six Sigma Black Belt from Pivotal Resources, Inc. & from ASQ

ISO: 9001 lead Auditor from Bureau of Indian Standard (BIS)

Exposure of implementation of the IMS (TS:16949, ISO:14001, ISO:45001 & ISO:50001)

Possess experience of supplier part quality, capability evaluation, gap analysis problem resolution

New part development, APQP process launch and supplier PPAP approval

Exposure of mass production of LMD Trucks with desired quality level & delivery target

Knowledge about the Vehicle Electrical circuit, ABS, AMT, Telematics, cruise control, Clutch setting & Vehicle geometrical parameters setting

Extensive experience in managing projects, Proto Builds, SOP to develop world-class products –Light & Medium Duty Trucks, Bus, Electric Bus & CNG vehicles

Career Highlights

5) VE Commercial Vehicles Ltd

Bhopal-MP

Section Head Mfg / Quality / Engineering

Since May2010

4) Asia Motor Works Ltd

Bhuj-Gujarat

Manager –SQIG

Sep’07 - Apr'10

3) QH Talbros Ltd

Gurgaon

Head QA-Quality Assurance & Systems

Oct’06 - Sep’07

2) Federal-Mogul Ignition Products India Ltd

Bhiwadi- Raj

Assistant Manager QA

Nov’04 - Oct’06

1) LML Ltd

Kanpur- UP

Assistant Manager QA

Jul'96 - Oct’04

Area of expertise

Manufacturing of Truck (03 Years)

Was overall responsible for Truck production with desired product quality level

Exposure of achieving Month production target

Manufacturing Engineering / Project Management (03 Years)

Lead program management for LMD Truck & Bus range, VDFA of class 1, 2 & 3 NPI Project related to Truck & Bus including CNG and Electric vehicles.

A, B & C proto builds, NCR Closure & SOP,

Line balancing, Training, Facility planning & execution

Documentation- station-wise BOM, FMEA, Control plan, AOS, WI

Export shop & Electrical Vehicle assembly shop planning & Execution.

Quality (18 Years)

Product & Process Quality

Process quality –Engine Assembly, Cab trim, LD Truck assembly & Two wheeler assembly

PDI inspection Engine,LMD Trucks & two wheelers

Machine shop quality assurance, Plastic molding process quality assurance

Process quality of Frame assembly & Front axle

Electric & Electronic components quality assurance– Spark plug, Wiring Harness, Magneto, Pick up coil, CDI Feeding coil etc.

Field complaints analysis & resolution

Supplier quality

New part development through APQP process & PPAP approval

Parts quality assurance- Sheet metal, Casting & forging, Machining, Plastic, Proprietary

Supplier monitoring, supplier assessment, Supplier Audit & CAPA

IMS Certification

IMS Certification of two plants (Pithampur & Bhopal plant)

TS16949 certification: VECV –Pithampur plant in 2012 and VECV- Bhopal in March 21

VE Commercial Vehicles Ltd Section Head Mfg. / Quality / Engineering since May2010

The unit manufactures and markets commercial vehicles with Gross Vehicle Weight (GVW) ranging from 5 to 40 tons. The manufacturing facility is situated in Central India Pithampur & Bhopal, MP. As a joint venture between the Volvo Group (Volvo) and Eicher Motors Limited (EML). The organization brings together global leadership in technology along with deep knowledge and experience of the Indian commercial vehicle market.

Key Accountabilities

At present working as functional head for Process quality assurance of LD trucks at VECV Bhopal plant since 2019

Achieved IMS certification of 4 standards (TS16949, ISO14001,ISO45001 & ISO50001) in Mar-21

Performed validation of new Engine line, Cab Trim & Truck assembly line at Bhopal plant.

Responsible for Quality gate inspection of Cab Trim and Chassis assembly process

Responsible for WAM, RBT, PDI inspection, Shower testing & road test of vehicles.

FTT improvement of WAM, RBT & Shower testing.

Responsible for Vehicle demerit reduction in assembly line less than 20 demerits.

Responsible for transit problems, dealer end issues & Field failures resolution & systematic closer.

Responsible for calibration activities

Monthly MIS compilation & improvement plan- review with management

Manufacturing Engineering / Project Management (2016 -2018)

Conducting VDFA of NPI Project of class 1, 2 & 3 project related to BS4, BS6, Electric Truck & Bus, Diesel & CNG vehicles.

Preparation of process related documents (AOS, BOM, PFD, PFMEA, Control plan etc.)

Prepare station-wise BOM for proper supply of parts. Co-ordinate with store engineering for line side parts storage facility planning.

Co-ordinate with Purchase, Production and QA team for planning & execution of proto/production builds on assembly lines. Piloting of in Proto shop, Method Shop or Assembly line.

VDFA & DFA NCR capturing and timely resolution with all stakeholders

Capturing and resolution of DFA NCR related to proto/method shop/production builds by conducting CFT meetings.

Tracking Engineering changes after SOP and its implementation.

Identification of man power training for new process and new models covering work man and supervisors

Truck Assembly (2013- 2015)

Manpower planning, shift planning

Achieve day production target as per PPC plan, analyze vehicle defects, daily QRQC

Co-ordination for Kaizen, VPS activity

Manpower training and defect reducing.

Line utilization improvement

Receipt Quality, QMS, Calibration & supplier management (2010 -2012)

Responsible for plant instruments calibration.

CMM inspection of Head and blocks for setup approval of machine shop.

TS 16949 certification of Pithampur plant in 2012

Aggregates quality assurance – Frame assembly & Front Axle assembly process & product audit.

Sheet metal, Casting, Machining parts, proprietary parts receipt inspection.

Supplier parts quality problem resolution through CAPA.

Supplier PPM monitoring and action plan to reduce the defects,

Supplier process audit and Parts qualification for DOL

Action plan for field failures related to parts, Frame & Front Axle

Established Front Axle shim selection process to avoid Axle failures for GSRTC Bus order

Established Frame bow & bend measurement system and controlled the parameters within 5 mm for GSRTC Bus order

Responsible to improve truck assembly line utilization and line rejections for part related defects

Low performing supplier monitoring and improvement plan

Asia Motor Works Ltd, Gujarat Manager -Supplier Quality improvement group Sep’07 to April’10

Manufacturer of Heavy commercial vehicles.

Key Accountabilities

APQP launch for new parts development and co-coordinate with supplier for PPAP. PSW Signoffs & PPAP approvals.

Develop facility planning for Parts and finalization of Quality plan with Supplier concurrence.

Agreement with Supplier for Lead time for development, Tooling, fixture, gauges, Logistics & Packaging and finalization of New Part Development Plan.

Follow-up with supplier for Gaps closure which is identified during initial assessment and verification of the actions initiated at supplier end.

Identification of gaps in supplier performance with respect to quality performance and initiate suitable actions to overcome the gap. Monitoring suppliers Performance Ratings & working with Suppliers to upgrade their Quality Performance.

Prepare road map to qualify the supplier for ISO: 9001 certification. Conduct supplier training program to upgrade their Quality management system.

Frame parts – Cross member, Bogie suspension Cross member development

Sheet metal fabricated parts SUPD, RUPD, Engine Mounting brackets development

U Bolt, DAT tank, Air Intake system, Fasteners, Ball joints, AC kit, Exhaust pipes, holistic parts development

Truck assembly problem resolution through G8D report.

Supplier process audit planning and execution

Supplier PPM monitoring and action plan

Parts field failure analysis and action plan

TS:16949 documentation for SQIG function

QH Talbros Ltd (Gurgaon) Head QA (Quality Assurance & Systems) Oct’06 to Sep’07

It is manufacturer of Steering & suspension components like Tie rod ends, Ball joints, and Drag links for Affinia (USA).

Key Accountabilities

Was responsible for supplier quality assurance for forging parts, Machined components and outsourced process and supplier quality improvement.

Quality assurance of CNC machine shop and assembly shop.

Machining set up approval and in-process inspection

Control in-house rejection and rework through execution of product and process audits and problem solving

Co-ordinate for CMM inspection of the component

Initiated Quality Circle activity to improve productivity and cost savings

Conducted in-house training programs on QMS, SPC, MSA, and PPAP to improve competency level of the subordinates.

Identification and implementation of continual improvement project for the Ball Pin, housing and assemblies.

Customer complaint resolution on customer specific formats

Established and maintained ISO/TS: 16949 & ISO: 14000 documentation

Involvement with design department and materials Team during development stage for smooth implementation of new products

Facilitated APQP activity

Prepare PPAP documents and submit to customer for approval.

Improved supplier part quality through planning and execution of supplier process audits

Federal-Mogul Ignition Products India Ltd (Bhiwadi) AM-Quality Assurance Nov’2004 to Oct’2006

It is manufacturer of Champion make Spark plugs for all Car & Two wheelers

Key Accountabilities

Quality assurance of forging shop of sparkplug shell

Quality assurance of Spark plug assembly process

PDI Inspection of spark plugs

PPAP submission to customers- Maruti Suzuki, Hero Motorcycles, HMSI, Hyundai, Bajaj Auto, Suzuki Motorcycle, Honda Siel, GM, Tata Motors, Eicher etc.

Attend customer complaints at customer plant

Customer complaint resolution and CAPA submission on customer prescribed formats.

Data compilation, MIS preparation and submission to FM-USA for review

LML Ltd (Kanpur) Assistant Manager QA July’1996 to Oct’2004

It was manufacturer of Scooter & Motorcycle

Key Accountabilities

Scooter & Motorcycle process quality assurance

Problem analysis & resolution related to Vehicle starting problem

Complete knowledge about the Vehicle Electrical & ignition circuit.

Implemented QS-9000 and ISO/TS: 16949 system in the QA function

Quality Circle activities, Conducting audits at vendor's premises

Team member of new vendor development

Training of the team members related to Scooter & motorcycle electrical circuit, including wiring harness, magneto, Feeding coil, Pick-up coil, CDI, Buzzer etc.

Conducting Measurement system analysis as per control plan

Training

ISO: 9001:2000 Lead Auditor course from BIS.

Undergone 30 days Vocational Training at Hindustan Aeronautics Ltd., Lucknow.

One-week training program on Application of Statistical Techniques for controlling the rejections-by Dr Tapan P Bagchi (Professor - IIT Kanpur).

5-day training program on Design of Experiment by Quality Growth services (P) Ltd., New Delhi.

Two day training program on Internal Auditor training of TS: 16949, ISO: 14001 by Quality Growth services (P) Ltd., New Delhi.

Two-day training program on Internal Auditor training of OHSAS: 18001 by DQS India limited.

Three-day training program on Dimensional Metrology at Accurate Engineering Pune.

Six-sigma Black belt training by Pivotal Resources, Inc. and ASQ.

Academic Credentials

Exam Institute Year %age

B.E B.I.E.T-Jhansi 1996 77%

12th U.P. Board 1989 60%

10th U.P. Board 1987 73%

Gate Score 87 percentile

Personal details

Date of Birth 10th Feb 1972

Linguistic Abilities English and Hindi

Address Flat No-207 A1 Balaji Heights, Indore M.P. 452010

RAJESH YADAV

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