Senior Quality Lead Auto/Heavy Fabrication
Resume:
KATHIRAVAN KALIYAMOORTHY
BE Mechanical Engineering Lead QA/QC Engineer Lean Six Sigma Black Belt CSWIP 3.1 Welding Inspector NDT Level II ISO 9001 & IATF 16949 Certified Chennai, India (Open to Global Opportunities)
+91-861**-***** **********@*****.***
linkedin.com/in/kathiravan-kaliyamoorthy-engineer
EXECUTIVE PROFILE
Strategic Supplier Quality Lead with 11+ years of global experience driving excellence in Heavy Fabrication, Automotive (Mining Trucks), Industrial Manufacturing, and Modular Fabrication environments. Recognized for delivering Zero Defect product launches, qualifying complex fabricated components, and spearheading New Product Development (NPD) initiatives for world class OEMs, including Caterpillar. Proven ability to align quality strategy with business objectives, lead cross functional teams, and ensure flawless execution across diverse, high impact projects. Recognized expert in APQP/PPAP, Product and process, audits, and NPD launch readiness with deep strengths in PFMEA risk mitigation, Control Plan optimization, PFC, run @ rate validation, Tooling readiness, Welding Integrity, Quality Requirements, CSR, SPC, MSA, and Cp/Cpk capability assurance. CORE COMPETENCIES
Quality Management
ISO 9001 with ISO/TS 16949 Internal Auditing QMS Deployment Compliance & Governance APQP PPAP (Levels 1–5) PFMEA Deep Dives Control Plan Optimization PFC Specifications reviews Gauge planning SPC MSA Tooling Readiness Welding & NDT
CSWIP 3.1 Welding Inspection ASNT Level II (RT, UT, MT, PT) WPS / PQR / WPQ ISO 3834 ASME IX AWS
Digital Quality (Quality 4.0)
Power BI Dashboards Python-based QC Automation Minitab (SPC, DOE) SAP QM Operational Excellence
Lean Six Sigma Black Belt 8D & RCCA VA/VE Poka-Yoke TIMWOODS Waste reduction KEY ACHIEVEMENTS
• Process Excellence: Established and maintained supplier quality standards (Quality Plans, procedures, inspection checklists, Quality Alerts), ensuring defect free products consistently reached customers.
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• APQP/PPAP Execution: Delivered complete and compliant PPAPs approved on first pass by leading PFMEA, Process Flow, and Control Plan development with customers, suppliers, and cross functional teams.
• Supplier Audits: Conducted PPAP aligned process audits at key supplier sites, identified gaps, and drove timely closure of findings, improving audit scores and process stability.
• Continuous Improvement: Applied Six Sigma, Lean, and QC tools to enhance process efficiency, reduce waste, and strengthen supplier capability.
• Root Cause & CAPA: Facilitated 5 Why and Fishbone analyses, implemented CAPA and mistake proofing on top defect modes, eliminating repeat nonconformances.
• Supplier Performance Management: Built and maintained supplier scorecards, conducted regular reviews, and tracked QDC metrics to drive accountability and improvement actions.
• Quality Documentation: Defined and released Quality Plans, QA Plans, inspection checklists, and Quality Alerts for critical parts and processes, ensuring defect free shipments to end customers.
• Domain Expertise: Proven experience in quality management within fabrication, welding, and machining environments.
• Standards & Core Tools: Strong familiarity with ISO 9001 IATF 16949 AIAG Core Tools (APQP, PPAP, SPC, MSA) ISO 3834 ASME Section IX AWS D1.1 EN 1090 ASME Y14.5 (GD&T) ISO 2768 ASTM ISO 8501/02/03 SSPC PROFESSIONAL EXPERIENCE
CATERPILLAR INDIA PRIVATE LIMITED
Lead Engineer – Supplier Quality Jul 2021 – Present
• Interpret customer drawings, technical specifications, quality requirements, and CSR, and cascade them to cross-functional teams (CFT)
• Coordinated engineering, manufacturing, purchasing, logistics, warehouse, and planning teams with suppliers to meet PPAP gate dates, OTIF targets, and ramp up plans for launches.
• Lead APQP, PPAP and ensuring effective execution of Quality activities for heavy mining truck structures, ensuring Zero-Defect Launch (ZDL) readiness across NPD and production programs
• Conduct Lean Manufacturing assessments and PFMEA deep dives for Special and Critical Characteristics (SC/CC) to proactively mitigate quality and process risks
• Reduced weld defects by 40% through PFMEA risk mitigation, WPS optimization, and supplier process audits across heavy truck structural weldments. Page 3 of 4
• Ensure Built-in Quality (BIQ) through the application of Lean tools, standardized work, layered process audits (LPA), and mistake-proofing (Poka-Yoke) methodologies
• Apply fact-based problem-solving and diagnostic techniques (8D, RCCA, process mapping, data analysis) to identify and eliminate process flow inefficiencies and variation
• Improved First Pass Yield (FPY) through SPC implementation and structured RCCA TATA PROJECTS LIMITED
Senior Engineer – QA/QC Mar 2019 – Aug 2021
• Executed QA/QC for high-value EPC fabrication projects across India and Dakar, Senegal
• Approved WPS/PQR/WPQ and performed NDT/visual inspections per ASME/AWS codes for heavy structural weldments
• Ensured weld quality, coating integrity, and dimensional compliance for large industrial structures
HARSHA EXITO ENGINEERING (P) LTD.
Assistant Manager – QA/QC Mar 2014 – Nov 2018
• Managed execution and commissioning of critical heavy fabrication EPC projects in India and UAE (Dubai, Ras Al Khaimah)
• Overseen production by monitoring manufacturing processes to ensure consistency and adherence to quality standards through inspections and test PREVIOUS EXPERIENCE
• Senior Quality Engineer — Harmech Industrial Equipment LLC (2015)
• Quality Engineer — Velmurugan Group of Companies (2012 – 2013) EDUCATION & CERTIFICATIONS
• Bachelor of Engineering (Mechanical) – Anna University
• CSWIP 3.1 Certified Welding Inspector (Valid through 2029)
• Lean Six Sigma Black Belt – Advanced DMAIC & Process Optimization
• Certified Quality Management Internal Auditor – IATF 16949 & ISO 9001:2015
• ASNT NDT Level II – RT, UT, MT, PT
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TECHNICAL & DIGITAL TOOLS
• Quality Tools: APQP PPAP PFMEA Control Plan SPC MSA Cp/Cpk 8D RCCA
• Standards & Codes: IATF 16949 ISO 9001 ISO 3834 ASME IX AWS D1.1 EN 1090 GD&T
• Digital Tools: Power BI Minitab SAP QM Python (Quality Analytics) AutoCAD PROJECTS & CLIENT PORTFOLIO
OEM Heavy Equipment Programs – Caterpillar
• Off-Highway Trucks (OHT) & Large Mining Trucks (LMT) – Truck Bodies, Frames and Operator Cabins; program involvement across NPD, ECN, CPPD, and AM
• Supported fabrication quality, supplier validation, and welding integrity compliance for heavy mining truck structural assemblies Structural Weldments – Heavy Fabrication
• Manufacturing and quality assurance of heavy structural weldments, vehicle body structures, Platforms, and high-load frames
• Welding procedure qualification and compliance including WPS/PQR validation and NDT inspections (UT, MT, PT, RT)
Modular & Industrial Fabrication Projects
• Heat Exchangers & Tube Shells – Client: Engineers India Limited
• Pressure Vessels – Client: Bharat Heavy Electricals Limited
• Stacker Reclaimer Systems – Client: NTPC Limited
• Kiln Shells and Rotary Cooler – Client: FLSmidth
• Wind Mill Tower – Client: Vestas and Gamesa
• Pre-Engineered Building (PEB) Steel Structures, Foot Over Bridge (FOB) with Cable (TRIL) – Industrial infrastructure fabrication projects LANGUAGES
English Hindi Tamil
REFERENCES
Available upon request
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