Avinash Sokhi

Pune, India +91-990******* adxewl@r.postjobfree.com

Professional Overview

sProject Manager in Process Excellence with 20+ years of experience in the Quality domain, specifically in the Manufacturing and Automotive sectors

sProficient in managing end-to-end New product development quality, encompassing customer, supplier, and plant aspects, with expertise in commodities such as Chassis, Transmission, Gear Manufacturing, Machining, Welding, and more

sLead Supplier quality role, for standardizing and streamlining the quality in supplier’s part. Through various initiatives like- Structured problem solving, continuous improvement, capability development, FMEAs, PPAP etc.

sInternal trainer for various quality tools like- 7QC, 5S, VSM, MSA, SPC etc., adept at facilitating knowledge transfer and skill development in quality system.

sDemonstrated international exposure, having successfully led quality initiatives in countries such as the United States and New Zealand

sSkilled in multiple languages, with an A1 level in Dutch and C1 level in English, fostering effective communication in diverse professional settings

Tech Stack

Quality Assurance:

sMSA (Measurement System Analysis)

sSPC (Statistical Process Control)

s8D (Eight Disciplines)

sFMEA (Failure Modes and Effects Analysis)

Quality Control & Quality Management:

sHands-on experience with measuring instruments (Vernier, micrometer, height gauge)

sNew Product Development Quality

sSound knowledge of IATF 16949 and ISO 9000

Software:

sConversant with MS Office

sGantt Chart

sSAP

sW-planner

sMinitab 14

Professional Experience

Omnex, India

Project Manager- Process Excellence March 2022- Till Date

Spearheading Process Excellence initiatives across the North and West regions, collaborating with esteemed clients such as UNO-Minda, Gestamp, Harman & Klassik Lamitex.

Executing comprehensive process assessments for clients to comprehend their current status, subsequently formulating and presenting tailored proposals for future growth in areas such as Operational Excellence, Design, New Product Development, and Quality

Identifying optimal tools, including 5S, Kaizen, Quality Circle, Just-In-Time, and ECRS, to facilitate improvements in operational excellence

Delivering training and guidance for the development of Key Performance Indicators, Standard Operating Procedures, Advanced Product Quality Planning, Production Part Approval Processes, Measurement System Analysis, and Statistical Process Control as part of quality enhancement; Moreover, facilitating Design Failure Mode and Effects Analysis, Return on Assets, and AS IS-TO BE mapping for design improvements

Recognizing and addressing Non-Value-Added activities to streamline processes by focusing on aspects such as Part Quantity, Part Product matrix, Takt Time, and Cycle Time

Conducting scheduled reviews of project progress with clients' senior leadership to ensure timely project completion and elevated levels of Customer Satisfaction

Demonstrating expertise in managing quality control/quality analysis organizations or leading cross-functional quality improvement projects and teams within a dynamic environment

Refining and establishing connections between an organization's Vision, Mission, Business Goals, and Policies

TATA Motors, India (CV & Defense)

DGM Quality April 2018- Nov 2021

Oversaw the comprehensive quality of New Product Development (NPD) support for domestic and international vehicles (trucks, tippers, and tractors) concerning both in-house and vendor components, in compliance with engineering modifications and regulatory standards

Identified project requirements based on design alterations and regulatory guidelines, initiating design action discussions with relevant stakeholders

Engaged with customers and monitored warranty claims (6MIS, 12MIS, 24MIS) to identify and address complex issues, with the objective of enhancing product quality

Collected failure data from suppliers and incorporated it into the Design Failure Mode and Effects Analysis (DFMEA) to establish appropriate Corrective and Preventive Actions (CAPA)

Collaborated with Design, Manufacturing, Test agencies, and Dealers to comprehend their needs regarding pain points and coordinated with the sourcing and Advanced Quality (AQ) teams to address product quality concerns

Evaluated and approved finished products following design actions, based on endurance and vehicle run test reports

Verified the implementation of design actions at vendor's facilities through audits as part of the new product development process

Worked closely with various departments and teams as Cross-Functional Team (CFT) members (Pune & Jsr) in conjunction with the Customer Service team, to mitigate field failures through DFMEA, Design Verification Plan (DVP), and Foundation DFMEA

Achievements:

Identified and capitalized on opportunities to enhance business connectivity and expand the existing platform portfolio

Integrated the Defense sector as a new platform within the current portfolio

Adding several critical projects to the existing portfolio, growing from 5 in FY 18-19 to 18 in FY 19-20, and 23 in FY 21-22

Established a structured approach to address failures related to supplier-designed products, known as "black boxes"

Cultivated a quality-driven culture through initiatives such as Daily Work Management, Warranty Walk Around, and Cross-Functional Team interactions

Led Plan-Do-Check-Act (PDCA) projects (2 in FY 20-21 and 5 in FY 21-22) with the objective of enhancing product quality to ensure high performance

Implemented a quality control process to address recurring field failures and ensure their resolution through concise one-pager reports

Pioneered internal training at Tata Motors Limited (TML) Jamshedpur by identifying and providing instruction on Design Failure Mode and Effects Analysis (DFMEA), Process Failure Mode and Effects Analysis (PFMEA), 8 Disciplines (8D), and Three-Legged Why-Why Analysis

Served as a Gold-certified Business Excellence assessor, conducting internal evaluations by engaging with various stakeholders and pinpointing areas for improvement

Acted as the Safety Single Point of Contact (SPOC) for 106 employees, ensuring compliance with TML's safety standards

John Deere India

Lead Supplier Quality April 2011- April 2018

Served as the overall quality lead for units assembled at the John Deere Dubuque facility in the USA, overseeing the process from raw materials to the finished vehicle, implementing agreed-upon modifications, and ensuring their sustainability

Verified machine audits, machine shake-downs, and rain tests

Monitored non-conformities and critical issues, escalating them to both internal and external stakeholders for proper root cause identification and resolution

Organized and conducted supplier audits according to the planned schedule to ascertain the root cause and ensure defect-free products

Maintained and controlled the quality of incoming supplier components to achieve zero-defect parts per million (ppm) at the plant level and customer end through Supplier Corrective Action Requests (SCAR) utilizing tools such as 8D, FMEA, Control Plan, and SPC studies

Thoroughly analyzed returned supplier parts and assisted in determining the root cause using the DMAIC approach

Conducted supplier assessments based on resource and organizational requirements, and provided input to the procurement team for qualifying suppliers for resourcing purposes

Achievements:

Following the assignment in Dubuque (USA), the existing profile expanded to include Crawler in addition to Skid Steer, with the objective of delivering seamless support for build-related quality activities from the organization

Transitioned from an individual contributor to managing a team of 10 members, providing necessary support in the Production Part Approval Process (PPAP) review for parts exported to John Deere's US facilities

Selected for the implementation of John Deere Quality and Production System (JDQPS) at Waratah in Tokoroa, New Zealand (July 2012)

Defined and deployed JDQPS requirements in product and process development at Waratah

Conducted process studies to identify risks and gaps (flow diagram, SWOT, FMEA) and offered improvement opportunities

Collaborated with operating staff to develop and create procedures, systems, and documentation, including Standard Operating Procedures (SOPs), Process Failure Mode and Effects Analysis (PFMEA), Control Plans, and Process Flow Diagrams

Appointed as Quality Lead for the first-time prototype build of Skid Steer in India

Evaluating suppliers' capabilities and capacities to undertake potential future work by validating their manufacturing capabilities, quality systems, and processes

Ensured part-to-print quality of Skid Steer

Collaborated with engineering, quality, and production teams at the supplier's end, specifying the product's quality requirements through PPAP, Design Process Approval Report (DPAR), and Final Goods Release (FGR), among others

Process improvement Projects:

Actively engaged in Root Cause Analysis (RCA) to address the skid steer boom squeaking issue in the United States

Assisted in the enhancement of weld quality for suppliers in India

Preceding Employment

sDeputy Manager (In-process/ Mfg) quality AMW truck, India Dec 2010- March 2011

sAssistant Manager QA (In-process & Supplier) & Business Excellence TRF India June 2007- Nov 2010

sManager QA and QC (In-process/Mfg) JMT Auto India April 2004 - March 2007

sEngineer Quality Industrial Ferro Product, India July 2003- March 2004

Education

sPost Graduate Diploma in Business Management specializing in Operations Management from Symbiosis, India, 2016

sBachelor of Engineering in Mechanical specializing in Automobile and Mechanical Vibration from Utkal University, India, 2003

Languages

sCompleted A1 level in German speaking from the Indian Institute of Foreign Languages, in 2020

sAchieved C1 level in English from the British Council of India, in 2019

Areas of Expertise

sRoot Cause Analysis

sStructured Problem Solving

sSupplier Quality Control

sProject Management

sTraining and Guidance

sAuditing

sStakeholder Management

sContinuous Improvement

sProcess Improvement

sCustomer Service

sManufacturing Quality

Contact this candidate