CAREER SUMMARY
A senior Management QA professional with a commanding 24+ yrs of experience in Quality assurance, Operation excellence and Supplier Management in Automotive and Engineering industries. Leading organization in expanding international footprints, building value, driving vision and achieving strategic goals. Contributed value for key strategic processing system and highly successful in establishing a scalable and sustained organization.
Adept in managing cross functional activities encompassing finished products QA / in-process QA / quality of the bought-out items and proficiency in coordinating with the vendors, enhancing their process operations; thereby achieving the required quality level in the supplies.
Dynamic change agent skilled in repositioning organisation to achieve operational and manufacturing excellence. Delivered dramatic improvements to Quality by leading organization to adopt TS16949, PED,ISO/IEC17025 and ISO9001:2008 and ISO 9001:2015.
Excellent analytical, troubleshooting and inter-personal skills with proven ability in driving numerous quality & Safety enhancement, process improvement and cost savings initiatives during the career span.
CORE COMPETENCIES
- Strategy Planning - ROI Accountability - Department Decision Making
- Plant Operations - QMS - Quality Assurance
- Process Management - Rejection & Re work Control - Supplier Development & Performance
- Client Handling - Documentation - Resourcing and indigenization
-Product Testing - Problem Solving - Statistical Tools
-Lean Management - Balance score card. - Continual Improvement
-Kaizen,5S - Best in Class safety practice
Certification
Qualified ISO 9001:2008 Lead Auditor By LRQA, UK.
Qualified ISO/IEC 17025 Auditor.
QS-9000, FMEA, Engineering & Managerial skills.
MSA & SPC , PPAP training at OMNEX India, Chennai
Qualified SIX SIGMA – Green Belt from ACMA.
Lean manufacturing.
Qualified ISO 9001:2015 Lead Auditor By LRQA, UK.Dubai
Qualified TS16949 Internal Auditor By UL India.
ASNT NDE level-II in MT/LPI/RT
ACADEMIC
B.Tech. in Production Engineering from MIT, Anna University with 82% of marks in 2003.
Post Graduate Diploma in Business Management with 75%
Post Diploma in Tool Design in CIT, Chennai with 75% of marks in 1997.
Diploma in Mechanical Engineering from P.A.C. Ramasamy Raja Polytechnic, Rajapalayam with 83% in 1994.
Membership
Member in American welding Society - AWS
Member in American Society of Quality - ASQ
Member in ASTM.
ORGANISATIONAL DETAILS
Since Aug’11 QA / QC Manager & MR (Senior Management Team)
Emerson Automation Solutions / Emirates Techno Casting, Sharjah, UAE (formerly TYCO Flow Control & PENTAIR)
A Leading steel casting & Cathodic Protection products manufacturer and supplying to customers in the Global Market.
April’10 - Aug’11 Manager – Supplier Performance Engineering
Comstar Automotive (Formerly VISTEON power train) , Chennai
A Leading MNC & Manufacturer of Starter, Solenoid and Alternator to the global Automotive market.
Sep’07-April’10 Corporate QA Manager & MR
Emirates Techno Casting, Sharjah, UAE: Leading steel casting manufacturer and supplying to 130 customers in the Global Market.
Mar’04 - Aug’07 Quality Head & MR
BorgWarner Thermal Systems, Chennai: Is a US based MNC & Manufacturer of Engine Component for SUV/ LCV/ HCV Application.
Aug’98 - Feb’04 Senior Executive-Quality Assurance
Rane NSK Ltd., Guduvancherry, Chennai: One of the Leading Steering Column Manufacturer for global passenger car manufacturers like Toyota, Ford, Tata, GM, MUL and HONDA.
May’94 - Jul’98 Management Trainee and Junior Engineer -QC
L.M. VAN MOPPES INDIA Ltd.: Member of Amalgamations Group, Chennai
KEY DELIVERABLES
Quality System Management
o Responsible for Developing and Implementing of:
? The Quality Management System across the organization.
? TQM activities in the Organization.
? Strategy , AOP and Goal setting of the Organization
o Preparation & Finalization of Quality Policy and Quality objectives for the organization.
o Coordination with certification agency for the:
? TS16949 / ISO 9001 Certification audits.
? Product audits like LR, DNV, TUV & BV.
o Conducting Management Review Meeting at frequent intervals.
o Managing the plant wise balanced score card process and Improvement
o Effective Implementation and Monitoring of Management of Change process across the organization.
Supplier Quality Improvements
o New Supplier:
? Assessment for quality system evaluation and approval
? Sign-off for new products & approve the tooling.
? Productivity / Quality Improvement program.
o Conducting Supplier PPAP audits and follow up for improvement points.
o Reviewing and Approving supplier special Process such as Welding ,NDE, Heat Treatment
o Reviewing and designing:
? Incoming parts inspection standards and work instructions
? Supplier quality assurance manuals.
o Overseeing supplier:
? Supplier Quality Performance and improve the same.
? Supplier process capability results and Improvements
? VAVE and Cost saving initiative with the supplier
Audit Management:
o Planning and conducting:
? Internal audit for ISO 9001:2000 & TS16949.
? Manufacturing process & product audits .
? Periodical Supplier process and systems audits.
o Co ordination with: national & international customer audits; customer for PPAP and process audits.
o Sketching and executing Layered audits.
o Review and effectiveness monitoring of the audit findings Corrective Action.
Documentation
o Implementing corrective and preventive actions for customer complaints.
o Technology transfer documents as actively involved in technology transfer
o Reviewing and approving of:
? Quality Plan, Control plan, FMEA, Process Flow, Packing Standard and Inspection Standard.
? Master documents from various departments.
? Process change / change management control documents.
o Preparing, reviewing and approving of:
? QMS manual, procedure and SOPs.
? Process, product and other audit plans.
o Sketching the:
? Checklist and issue for various audits.
? QA plan chart for New Product.
Standard Room & IMTE Control
o Procuring new instruments and test equipment
o Implementing calibration procedure for all Measuring and Test Equipment.
o Conducting Measurement System Analysis for all IMTE.
o Reviewing IMTE calibration.
In-process and product quality planning
o Responsible for analysis of:
? In-house quality problems and initiate countermeasures.
? Internal rejection control through Pareto Analysis, Cause & Effect Diagram.
? Cost of poor quality and reduce the COPQ
? Process capability studies and Review of control charts.
o Conducting review on:
? Patrol Inspection of In-House Assemblies/Sub-Assemblies/ Machining operation in house.
? In Layout Inspection, Product audit results.
? Investigation of:
- Deviations, Non-conformances, Out-of-specification, Out-of-trend and change controls.
- Pre-Delivery (Audit) Inspection of finished products
Special Process Approval
? Review and Approving of Heat treatment processes
? Review and Approval of Non Destructive Processes , Qualification of NDE personnel and monitoring according to ASNT , ASME and EN international standards
? Review of WPS/PQR , Compliance of welding processes to ASME and EN international standard
? Controlling of Plating , Injection mould and Painting suppliers.
Client support:
o Liaising with customer for quality concerns and complaints through problem solving techniques.
o Review of customer score card / customer rejection parts analysis
o Investigating on field returned components and suggesting corrective and preventive actions.
Continual Improvements
o Reviewing of Process capabilities of critical parameters and initiate process improvements.
o Leading continual improvement based on the Internal Audit / Product Audit / Process Audits.
o Implementing VA / VE concepts implementation.
o Implementation of Lean and six sigma .
Lab testing in-charge :
o Preparing test plans in liaison with Engineering & PED for new product testing.
o Reviewing & controlling Functional Testing of Products as per Revalidation Test plan.
o Managing the state of the art ISO17025 Laboratory.
Training detection & General administration
o Grounding Training syllabus and training needs relating to quality aspects.
o Imparting training on shop floor and at supplier manufacturing locations
o Developing / Mentoring Team development
o Managing the team of 100+ and monitoring the performance management of the team towards achieving the organizational targets.
o Making Quality Budgets , capex and supporting organizational budget preparation.
o Equipment selection and finalization of the Quality and Key special processes .
NOTABLE FEATS
Obtained certification from TS16949 and ISO9001:2000 with in 8 months. BorgWarner
Reduced customer end rejection level from 2800 PPM to 132 PPM BorgWarner / Rane NSK steering Systems.
Increased the acceptance level of Bought out(Receipt) parts from 5000 PPM to less than100PPM. BorgWarner / Comstar Automotive / Emirates Techno Casting
Established the:
o Manufacturing & Assembly Line from overseas plant to India plant.
o Product test laboratories to validate the products and Standards room for calibration.
Played a stellar role for implementing:
o SPC & MSA in all the organization.
o Layered Audit system.
Functioned as a leader for the organization towards:
o Continual improvements through implementing Poka Yoke, VA/VE and Problem solving Technique.
o Successful certification from PED and NORSOK
“Excellent Performance” rating & award since last 5 yrs.
Implementation of ISO 9001:2015 in 12 weeks.
Many Cost reduction and Process Improvements across the organization.
INTERNATIONAL EXPOSURE
BorgWarner plants in UK-Bradford, China-Shangai and Germany - Markdorf for a month to study the process for localization of parts in an Indian plant.
Many international industrial Valve and Earthmoving Equipment manufacturer – Germany / France / UK / Italy / singapore.
REFERENCE
V.D.Umashanker ,
Managing Director – BorgWarner
Mobile# +919884086000
Mr.Antonio Cafaro,
Managing Director – Middle East & Italy. (Retired)
Tyco / PENTAIR – Valve & Control Business.
Mail Id: antoniocafaro@alice.it / +39335465884