Bharat — Quality Assurance Engineer

Quality Review of NPI projects, / Assembly Productivity, NCM/RMA/MRB, ISO/AS 9100, AS9102, ISO 13485.  QMS - KPI Review: CI-Kaizen-Lean Sigma, MRB, FAI, RI-CP, (Scrap, Rejects, and Complaints) Analysis.  Provided Guidance, Training, and Leadership and Reviewed OEE Performance / QMS - KPI Analysis.  Market: Defence, Space/NASA, Aviation (Boeing, Worldwide Governments), Lockheed Martin, and Commercial.

AIAG (APQP-PPAP): NPD/NPI/ECN, New Tool, Supplier Relation Review, CSR Review for deliverables.  KPI Review: CI-Kaizen-Lean Sigma (Scrap, Customer Complaints, Downtime) for RPN Analysis.  Monitor Supplier performance / Scorecard. Review and address supplier product quality-related issues and concerns

Led 4th, 3rd party IATF 16949 compliance Audit, and passed it with flying colors (July-2020) and Customer Audits,  Continuous Improvement KPI: Monthly QMS Review RMA-NCM /GP 12/ 8D, Scrap, and Customer Complaint.  KPI Review: Daily OEE KPI Review, (Scrap, Customer Complaints, Downtime) Productivity Improvements, GP-12.  Created Calibration and various Audit Metrics (Internal, LPA, Customer, and 3rd party) – KPI  Mentored, Coached Quality Team in problem-solving tools, Gemba approach, and AIAG Tools CP, FMEA, RPN Review

Continuous Improvement - Lean Sigma: Addressed customer quality concerns (VOC, 8D, RCA, BMW, Tesla & Ford).  Performed weekly LPA. Participated with engineering team NPD and Run at Rate and Process Validation. 1  Training: Led New Hired Employee Training focusing on Quality-Productivity (WI, Visuals, Documentation, etc.).

Led IATF 16949 Certification (Feb 2018), Ford Q1 Audit, China CCC-CCAP Compliance Certification,  AIAG Tools (APQP, PPAP, MSA, SPC, FMEA), Quality Tools,  Continuous Improvement – Lean Sigma: Internal, external and New Product Project Quality Concern (Ford) KPI

Established guidelines for ISO and EHS implementation and addressing customer complaint and warranty issues.  Prepared APQP, PPAP, MSA, SPC, FMEA (AIAG Tools) for Customer submission and Approval.

CI-Kaizen-Lean Sigma contribution and accomplishments:  Recommended Multiple Cost Saving IDEAS: $375K Q-Team, Production and, $1.2 M, pasting process.  Led various projects for productivity, and efficiency improvement (cost saving of $ $1.5 M, Tylor, Mike).  Mentored and coached direct reports in Gemba - problem-solving technique, reducing line rejects. (Post Height).  Recommended plans for Line Rejects reduction (Final Testing and Labeling Process), CI, and Cost Saving.  Mentor Engineer for SSBB project and Certification.

GM – CORVETTE 2014 model and Chrysler Jeep Cherokee 2016 model new product launch – as NPD Quality Engineer.  AIAG – APQP/PPAP, NPD/NPI Pre-Production, Production Introduction and Post-Production.  Continuous Improvement-Kaizen-Lean Sigma – KPI: Line Rejects eliminated (EC), Design review-modification  Improve dimensional Integrity and stability, Molding – assembly processes – KPI

Led CI-Kaizen-Lean Sigma projects Customer complaint 50% and increased productivity 33% (Tool Design) – Bullard.  Led 3rd party, ISO 9001-2008 compliance certification audit successfully.  Led New Product introduction with ZERO DEFETC goal (18 tools from Dana Corporation), successfully

Continues Improvement / Kaizen-Lean Sigma contribution and accomplishments:  Led Kaizen Project saving of 1000 hrs. in shipping department by eliminating non-value-added activities.  Cost reduction of 75% in Pre-Press. Removed bottleneck resulting in cost saving of labor = $50,000 / year.  Investigated late shipment issue and provided solutions eliminating bottleneck resulting in a reduction of backlog.  Led ISO-9001-2008 compliance certification, Internal and customer audits.

Led New Product Launch / NPD SPC analysis AIAG / PPAP: MSA / PPAP / Gage R&R / CAPA / 8D / HACCP.  Monitoring of AIR Quality to meet GMP / FDA / HACCP guidelines / ISO 13485 (White – Clean Room) requirements.  CI-Kaizen-Lean Sigma Contribution and Accomplishments:  Improved NPD trials timeline by 50 %. And eliminating bottlenecks. (CI-Kaizen-Lean Sigma).  Reduced Dimensional Process Capability Studies timeline by 50%. (CI-Kaizen-Lean Sigma). 2  Elimination of overtime with savings of - $90k. (CI-Kaizen-Lean Sigma

Continuous Improvement / Kaizen, Lean Sigma – KPI:  Improved paint line production 25 %, reduction of production rejects 30%, increased in production process capacity 30 %  Leader and Mentor for waste reduction project that resulted in cost savings of $1,000,000 (Machine Improvement).  Led CI-Kaizen project in finish and repair dept. reducing repair time 50 % also reduced waste.  Mentored and trained team-Leads / supervisors-managers in Lean Tools for cost savings and waste reduction.

Led IATF 16949, 3rd party compliance Audit with flying colors (reduction of 11 Major -2018 to only 3 Major)  Continuous Improvement - Lean Sigma methodology for OE - KPI Led Gemba Team (Introduction, Training).  AIAG Tools: APQP, PPAP, MSA, FMEA, SPC +

Continuous Improvement-Kaizen-Lean Sigma-KPI.  Successfully implemented (in 6 months), monitored and maintained QMS (ISO 9001 / QS-9000 / TS16949).  Initiated innovative approach of Quality by partnership with customer (i.e.: Honda), Introduction of X-Rite/Color Match