Continuous Improvement Manufacturing Engineering
Resume:
©Majid Ali – All Rights Reserved
Majid Ali
Personal Details
Based: Birmingham B9 5TQ Mobile:
Email: ***.*******@*****.***
Professional Summary:
“An innovative Engineer with a proven ability
to resolve technical problems and
system deficiencies across a range of manufacturing sectors”
• Manufacturing Engineer driven by Continuous improvement within faced paced, high volume manufacturing settings.
• Internal/external auditor ensuring ISO 9001 compliance, corrective action implementation and supplier quality assessment (SQA).
• ISO 9001:2015 Auditor Certified.
• Six Sigma Yellow & Green Belt trained.
• Worked within ISO 13485 with Medical devices.
• Supplier Development – Client relationships through a mutual achievement, facilitating a ‘continuous improvement’ attitude.
• Inspection of Precision components for Rolls Royce with the use of various measuring devices.
• In-depth knowledge and understanding of IATF 16949.
• Results driven and comfortable working to tight time line deliverables.
• Working to the philosophy ‘Plan-Do-Check-Act’ and promoting this attitude within my team.
Core Skills
• Lean Six Sigma Yellow and Green Belt.
• ISO 9001:2015 Auditor Certified
• Technical Analysis / Root Cause Analysis / G8D/NCR.
• Problem Solving.
• Quality Management.
• Lean Manufacturing.
• Preparation of PPAP / PSW
• Generate and Review Control Plans, PFMEA and Process Flows.
• Working with Medicinal Products as per ISO 13485.
• Supplier Development.
• Project Management.
• Time Management.
©Majid Ali – All Rights Reserved
Education & Qualifications:
2002-2006: University of Wolverhampton BEng
(Hons) Manufacturing Engineering
1998-2002: St Philips Sixth Form College
AVCE Information Technology
Employment History:
Jan 2023 - On going at Gestamp Automotive
• Successfully completed IATF 16949 training
• Monitors SPC data to ensure delivery of consistent quality from suppliers or to customers.
• Complete scheduled process audits in line with IATF standard
• Carry out problem solving activity using the Global 8D methodology
• Update Control Plans & PFMEA
• Responds and follows up on customer and supplier concerns with regard to quality
• Plans and coordinates PPAP documentation and submissions to customers and coordinates and approves supplier PPAPs.
• Assists with CPs, PFMEAs and other APQP launch activities for customers or suppliers.
• Assists in the development of standardized work processes and process improvements.
• Update customer portals as needed
Apr 2023 – Dec 2023 Alstom Railway Project Quality Engineer (Six Sigma) Contract
• Review and manage 8D reports through the problem solving tool (PST)
• Driving continuous improvement methodology by implementing lean tools
• Application and improvement of Quality tools i.e. (PPAP, FMEAs and Quality Gates)
• Monitor the performance of any tools used
• Mitigate any risks with the use of the 8D process
• Communicate performance, risks with other departments and stakeholders
• Working closely with customers to ensure customers are satisfied with end product
• Project Management
• Working at own initiative and as part of a team
Jan 2023 – Mar 2023 Supplier Quality Engineer (Auditor) at Caudwell Marine
(Contract through Global & Partner)
• Project Management
©Majid Ali – All Rights Reserved
• Managing and Performing Supplier Audits
• Monitor Supplier Performance and on-time delivery
• Working closely with Suppliers to resolve Supplier constraints and improve Supplier Performance
• Evaluate Supplier risk to customer and implementing correct preventative tools through Lean Six Sigma
• Improve RFT Supplier submission of FAIR’s
May 2022 – Dec 2022 Plant Quality Engineer at Caterpillar (Contract through Global & Partner)
• Managing Caterpillar BIQ (Built in Quality - lean project).
• Reviewing daily/weekly non-conformances and implementing corrective actions and countermeasures to eradicate repetitive defects.
• Drive change daily through 8d methodology and regular review and report progress through KPI to Senior Management.
• Improving departmental DPU from 17dpu (defects per unit) to 2dpu with the implementation of correct lean tools and continuous improvement methodology.
• Ensuring management teams are held accountable to lean team and are on track to meet overall project objectives.
• Ensure all process control documents are valid and compliant to written process.
• Holding daily meetings with shop floor managers and producing minutes and task delegation and to drive and monitor lean project progress. Sept 2021 – April 2022 Operational Quality Engineer at Department of Health and Social Care (UKHSA) Contract
***Strictly CONFIDENTAL***
● Carrying out compliance checks on Medical Devices.
● Working with ISO 13485.
● Carrying out Audits on processes that don’t adhere to ISO 13485 certification
● Working on Stock Reverse logistics to ensure all stock is accounted for and segregated accordingly.
● Reverse stock project management.
● Ensuring all non-conforming items are recorded using the UKHSA Quality standards system.
● Raising Quality Alerts and notifying relevant departments to ensure correct SCAR is raised accordingly.
● Implementation of Corrective Actions to eradicate any repeating non- conformances.
● Working at own initiative and as part of a team
Aug 2019 - Dec 2020 Quality Supervisor at Makita ● Implementation of PFMEA.
● Managing a Team of Quality Inspectors to ensure all parts booked on at Goods inwards are inspected in line with Makita process/procedures in a timely manner.
©Majid Ali – All Rights Reserved
● Monitor supplier performance with the use of Quality Maps system to ensure suppliers are adhering to the Quality standard code.
● Working closely with UK and EU Suppliers to improve Supplier performance.
● Working closely with Suppliers to ensure Suppliers adhere to SCAR responses. in a timely manner with robust countermeasures.
● Conduct Quality Audits at Supplier facilities to measure the effectiveness of countermeasures implemented.
● Ensure effective closure of Supplier Corrective Action Report (SCAR) and 8D is achieved.
● Arrange and coordinate Quality meetings in order to effectively resolve Quality concerns and issue minutes with defined actions and timeframes for internal and external non-conformances encountered .
● Undertake investigation of quality problems (product, system, process etc.), utilising appropriate department staff, support departments with problem solving techniques.
● Conduct MMS (Makita Management System) and process audits in line with company procedures.
● Working closely with other departments within the business (Product Engineering, Production Control and Commercial) to ensure all areas of the business are aware of any non-conformities when interacting with suppliers
● Implementing Kaizen activities to ensure continuous improvement within the Quality department.
● Use of various measurement devices.
● Computer literate, knowledge of Microsoft packages. Feb 2017 – Dec 2018 Quality Engineer at Ricor
● Support Projects team with PPAP, Control Plans, PFMEA and PSW sign offs. ● Ensuring manufacturing control at point of manufacture.
● Ensure all supplier concerns are raised back to the supplier and review 8D’s. until closure and any off standard is recovered using the GRN system.
● Support Quality technician on each shift.
● Lead Problem Solving activities & compile Corrective Action Reports.
● Analysis of measurement data to establish further actions with the engineering department.
● Carry out Courtesy visits to customer location/customer liaison. ● Carry out Courtesy visits to supplier location/supplier liaison.
● Maintain documented Quality System (updating documents etc)
● Observe Company Health and Safety Regulations whilst carrying out your duties.
● Communicate at all levels within the company.
● Work in a team working environment.
Nov 2016 – Jan 2017 Quality Engineer at AER Stafford Ltd – Norton Canes
(Contract)
● Ensure all supplier concerns are raised back to the supplier and review 8D’s until closure and any off standard is recovered using the GRN system.
©Majid Ali – All Rights Reserved
● Supporting customer concerns off site when requested.
● Supporting system audits and shop floor audits as planned by quality manager.
● Support TS16494 + ISO 14001 audits as and when required.
● Control all non-conforming parts to quality procedure.
● Carrying out material tests such as Dyne tests and flatness tests using various measuring equipment.
● Resolve quality issues of capability, teleroncing, and material related issues.
● Resolve quality issues by identifying problems, examining solution options, implementing action plans, and providing resolutions. Aug 2016 - Nov 2016 Lettings Manager at Shipways Estate Agents (Details available on request)
Sept 2015 – July 2016 Quality Engineer at Sertec
● Supporting all customer concerns and CARs and ensure robust containment is in place.
● Supporting shop floor teams with problems and team development to ensure Quality is maintained.
● Ensure all supplier concerns raised back to the supplier and review supplier 8D’s until they reach closure. And any off standard is recovered using the GRN system.
● Supporting customer concerns off site when requested.
● Supporting system audits and shop floor audits as planned by Quality Manager.
● Support TS16949 + ISO14001 audits as and when required.
● Control all non-conforming parts to quality procedure.
● Supporting customers with regular site visits and attending requested meetings.
● Using Problem solving tools to identify, correct and eliminate recurring problems by using 8D/FMEA/Six Sigma.
● Making use of APQP/PPAP/PSW’s.
● Carrying out Macro Tests on Aluminium and Steel parts, as well as using Shadow Grafts for Metal Porosity & Fusion Test results. ● Carrying out Acid tests on steel parts.
Aug 2014 – Sept 2015 Quality Support at Sertec ●
Responsible for the Quality Department.
● Carrying out destruction tests on parts produced for Jaguar Land Rover.
● Carrying out tests that meet customer requirements from torque test to a hammer
& chisel test on parts produced.
● Making sure customer requirements are met and 100% quality is achieved.
©Majid Ali – All Rights Reserved
● Using hand held measuring tools such as a Vernier to measure the spot weld once a destruction test has been performed.
● Resolving customer concerns that could potentially lead to the customer.
● Recording all test data and corresponding to the operations manager on daily basis.
● Liaising with quality engineers to ensure all parts produced have the relevant documentation to support the production of parts produced.
● Reporting to the quality engineers of any possible risk factors involved with the production of conforming and non-conforming parts produced. ● Eliminating defects that can effectively stop production at JLR. Feb 2014 - June 2014 Dimensional Quality Inspector at Clamonta
● Working for a reputable Manufacturing company that Manufactures precision parts within the supply chain of Rolls Royce.
● Checking dimensions of precession parts manufactured using the hand measuring equipment such as verniers, caliper, micrometer, blade-mics and other traditional measuring devices.
● Working from engineering drawings and understanding the parts that need to be measured Carrying out final inspection and completing relevant checks
● Reporting any issues found to be incorrect to the Quality Engineer
● Transferring parts to the rework department to eliminate defects from products manufactured and making sure 100% quality production has been achieved.
● Working to tight tolerances with manual measuring equipment such as Vernier micrometer, gauges, shadow graph etc.
Sept 2013 - Feb 2014 Quality Inspection Supervisor at Aktrion
● Managing quality department at re-work area and quality inspection for a Leading Automotive Company and providing effective quality inspection at various sites such as BMW, and Faurecia.
● Inspection and rework of Engine Harnesses, Battery cables and Transitions.
● Responsibility for the Quality Department.
● Liaising with our client on all aspect of work.
● Liaising with the logistics department for stock management.
● Undertaking problem solving exercises.
● Ensuring all re-works are carried out following the guidelines on work instructions and drawings for accurate measurements.
● Quarantine any products that need to be re-worked.
● Corrective action follow up.
● Initiating and coordinating improvement activities.
● Customer liaison on product quality issues.
● Use of various measurement devices.
● Computer literate, knowledge of Microsoft packages. Sep 2011 - Aug 2013 Part Time (weekend) Supervisor at Replay House of Fraser, Birmingham
©Majid Ali – All Rights Reserved
(Details available on request)
Sep 2009 - Dec 2010 Sales & Lettings Manager at Set Homes Estate Agents
(Details available on request)
Sep 2007 - Jun 2009 Sales & Lettings Negotiator at Boss Estates
(Details available on request)
Jul 2006-Sep 2007 Quality Inspector at Denso Manufacturing UK
● Responsibility for the Quality Department
● Checking the position of holes, weight and density of holes along with many other checks.
● Identifying and eliminating defects by using the Japanese method of Lean Manufacturing principles on Air Conditioning units and radiators for the Automotive industry.
● Harness Inspection - (Checking Connectors and plugs for accurate fittings) making sure all electrical wiring harness were checked to ensure full function.
● Use of various measurement devices (Vernier, calipers, micrometers, blademics).
● Performing First off checks .
● Carrying out final inspection.
● Undertaking problem solving exercises.
● Customer Liaison.
● Producing quality/inspection reports.
June 2005- Dec 2005 Project Handler at Omron Electronics
● Working as part of a team for a new EPAS System for the Honda Civic 2006.
● Quality Inspection & undertaking relevant rework.
● Finding ways to reduce TAKT time and increase productivity.
● Eliminating Defects as part of a 100% Quality Formation. ● Working in a Lean Manufacturing Environment.
Contact this candidate