• Gender: Male
• Age: 44
• Designation: Manager
• Highest Education Level: Post Graduate Diploma
• Current Gross Salary: INR  5 /Annum
• Expected Gross Salary: INR  7 /Annum
• Preferred Country: India
• Notice Period: 30  Days
• Work Experience: 20.8 Year(s)

Education

Pursuing MBA in IGNOU

Post Graduate Diploma in Quality Control Management from IIMRT

B. Tech First Class from Adhiyamaan College of Engineering in May 2002

Skill Sets

Six Sigma, SPC, FMEA, Lean Manufacturing, Engineering, New Product Development, 5S, Continuous Improvement, Good Manufacturing Process, Good documentation Process, Testing of Plastics, General Management
ISO – QMS, ISO – EH & S, Quality Function Deployment, Recruiting, Training, People Development, PPAP

Work Experience

Manager - QA
Since Feb 2014
Company Profile: A Customizing, Manufacturing and meeting the watch strap requirements of watch companies in India and internationally. The units are equipped with up to date Swiss and Italian machines to handle the complex process of converting the finished leather to fine straps, with a combined capacity to produce up to 4.5 million High Quality Straps per annum
Job Profile:
Ensuring Zero customer rejections and FTA at customer end.
Ensuring the product with regard to Quality at all stage, i.e., from incoming to Final Inspection.
Ensuring Products meeting the legal requirement.
Ensuring Customer requirements are communicated and understood by everyone.
Vendor questionnaire preparation.
Handling of Customer audit.
Monthly, daily report preparation and communicating to Top Management.
Preparation and execution of CAPA for internal failure / Quality issues.
Developing supplier to align with the Customer requirement.
Internal problem solving.
Setting up / alter the process to make sure the quality requirements are met.
Heading CFT to resolve the quality issues.
Online rejection analysis and control, reduction of rework.
Implementation of error proof system/ process to meet the customer Quality requirement.
Participating in New Product Development.
Deviation approval/ Validation.
Preparation of SOP, WI, Pictorial procedures, Do’s and Dont’s.
Implementation of SPC.
Preparation of Quality plans.
Preparation and implementation of test procedure
Internal auditing.
SRV approval.
Training.
Batch release.
Technical Data Sheet review and approval, Control plan approval.
Inspection report Approval.
Ensuring the organization is regularly performing 5S.
Major Operation: Bench cutting, Splitting of the leather, Skiving, Gluing, Inlet fixing, Moulding, Stitching, Printing, Slotting, Hole punching, Assembling
Reporting To: General Manager

Sr. Engineer - (Designation – Sr. IPQC)
April 2011 to Jan 2014
Company Profile: Specialises in rigid plastic packaging, drug delivery systems and medical devices for pharmaceutical, medical and biotechnology companies. Using in-depth expertise in plastic injection and high-speed automated assembly. Offers the widest product range on the market: drug delivery systems, medical devices, metering pumps and valves, plastic primary packaging and diagnostic disposables
Job Profile
Entire clean room Quality Control Responsible: Reviewing all shift – IPQC log book and reports & defect incidence report & perform daily rounds.
Conducting daily meeting with operation team to review daily Quality issues.
Line clearance verification, Start up report preparation, trial report preparation, FAR & product qualification reports
Preparation of CoC & CoA
Verification of OOS & CAPA for OOS obtained.
Online Rejection Analysis & Control
New Product development & Innovation
Packing materials evaluation
Participating in Quality Audits
Control plan Preparation For All Products
5S zone leader and auditor for other zones.
Incoming & Final Inspection
Performing Six sigma project.
Customer complaint Analysis.
SPC Analysis based on the customer requirements.
Conducting R&R studies for equipments.
Calibration of equipments.
Functional checking based on the customer Specification & train the IPQC for new equipment and technical requirement.
Monthly rejection analysis and control
Review and Approval of BMRs
Validation of new moulds
Preparation of Vendor Questionnaire
Batch release in SAP.
Rework, Deviation, Customer complaints Logging and verification.
Preparation of CAPAs for customer complaints.
Internal calibration of Weighing machines and Accuracy precision study for the same
Internal EH&S auditor.
Preparation of Pareto based on the incidences for tool and process improvement
ISO documents (SOPs, Work instructions, Formats revision and control
Authorized trainer for the operators.

Position Overview: Overall Responsible for, Documentation control, Inprocess Control, Calibration Control, Product Validation, Testing of Packaging material, Preparation of SOP, SPC Analysis, Resolving Customer complaints, Customer complaint Analysis & Root cause Analysis.
Major Operation: Injection Moulding, Injection Blow moulding, Assembly, Packaging
Reporting To: Quality Manager

Senior Quality Engineer
December 2008 to April 2011
Company Name: Manjushree Technopack Ltd.,
Company Profile: Rigid plastic packaging provider to institutional buyers which include top FMCG names like the Unilever Group, Glaxo Smithkline, P&G, Cadbury, Nestle etc. Manjushree Technopack Ltd (Incorporated in 1987) makes PET - Jars and Bottles, PP - Jars and Bottles, Co-extruded Multilayer Containers, Hot-Fillable PET Bottles and Injection Molded Products. Manjushree is an ISO 9001:2000 & ISO 22000:2001 certified company and won awards like India Star Award 2004, Asia Star 2000 award and Plast India Award.
The company has diversified into manufacture of PET Preforms during FY 2008 having a focus on carbonated soft drink sector and packaged water industry with major international players like Coca Cola, PepsiCo & Bisleri. Producing 2.5 million Preforms / day.
Job Profile
Incoming, In process and final inspection
Conducting SPC for process, mould and machine Capability
Calibration and Maintenance of Measuring and Monitoring Equipments
Preparation and control of product manual and distribution control of SQA manual such as Control plan, standard operating procedure (SOP), Incoming Inspection plan, colour coding for easy identification of products.
Customer complaints & Root cause Analysis, Implementation of Corrective action & Preventive action.
Trained in-house engineers in SPC, 7 QC tools & Gauge R&R.
Online rejection control.
Preparation of Quality documents based on customer requirements.
New product development.
Packing materials evaluation.
PRP,OPRP Inspection & monitoring.
Specification Sheet Preparation For All Products.
Designing and implementing stringent systems and Quality plans to ensure high quality standard of materials.
Identifying supplier specific quality issues and developing & implementing solutions to improve the technical conformity of the products.
Conducting Hazard Analysis.
ISO 22000 Requirements like Pest control audit & Glass audit.
New product development.
Product testing : for Preforms – crystalinity, wall thickness, gauge check, moisture content, polariscopic check etc.
For bottles – stability, wall thickness, top load test, volume check, drop test, etc.

Position Overview: Overall Responsible for, Documentation control, In process Control, Calibration Control, Product Validation, Supplier Quality Assurance, Testing of Packaging material, Preparation of SOP, SPC Analysis, Resolving Customer complaints, Customer complaint Analysis & Root cause Analysis.
Major Operation: Injection Moulding, Blow moulding, Assembly, Packaging development, Sleevings
Reporting To: Quality Manager.

Managing Director.
January 2008 to December 2008
Company Name: Trimuti Plastics
Company Profile: Vendor for TVS groups (an automobile tyre- 2 supplier). And also manufacturing regular plastic and wooden hangers, polythene bags to polythene bags of various styles in different materials, corrugated boxes, tags, collar patties, butterfly, PVC pouches and Boxes, laminated films and pouches for the FMCG markets
Job Profile
Incoming, In process and final inspection.
Internal Complaints handling and Problem Solving through 8D Techniques.
Conducting SPC for process, mould and machine Capability.
Calibration and Maintenance of Measuring and Monitoring Equipments.
Preparation and control of Product manual and distribution control of SQA manual such as Control plan, Standard Operating Procedure (SOP), Incoming Inspection plan.
Supplier Quality system evaluation i.e., Supplier’s abilities towards development of components.
Trained Suppliers and in-house engineers in SPC, Control Plan, 7 QC tools & Gauge R&R.
Handling line rejection meetings with Subcontracting Vendors and Inhouse Production heads.
Sample preparation for customer approval.
Preparation of weekly rejection analysis report and implementing corrective and preventive actions for control of non conformities.
Preparation of Quality documents based on customer requirements.
Packing materials validation and Release. And production activities such as
Preparation of raw material indent.
Process trouble shooting.
Production planning.
Man power allotment

Position Overview : Overall Responsible for, Documentation control, Control Plan Audit, In process Control, Calibration Control, Product Validation, Supplier Quality Assurance, Testing of Plastic raw materials and Packaging material Evaluation for all five units. Assisted MR in QMS implementation and maintaining the QMS for all five Units.
Major Operation: Injection Moulding, Assembly, Packaging development, Decorative techniques like printing
Reporting To: Managing Director

Engineer
June 2004 to Dec 2007
Company Name: Carbonaire Industries Madras Pvt Ltd
Company Profile: An ISO 9001:2000 Certified Automobile industry. Major vendor for Rane, Ford, IFB, Saralee Indian Railways, UK Railways, German Railways and Sri Lankan Railways. It is involved in Mould design & development, manufacturing and assembly of Automobile Components. Three manufacturing plants in Chennai with a turnover of around Rs.80 Crores per annum.
Job Profile
Preparation and control of PPAP Documents and submission to customers.
Customer interaction including customer inquiries and Customer complaints handling and problem solving through 8D Techniques.
New Product component validation and Product release for production.
Preparation and Control of Quality Assurance Plan (QAP) for Railways.
Planning and Conducting MSA and CPk Studies.
Testing of Plastics Raw materials as per ASTM, DIN, ISO, BS, BIS and Railway Standards
Tensile strength ad Elongation.
IZOD and Charpy Impact Strength.
Melt Flow Index (MFI).
Specific Gravity, Melting point and Water Absorption.
Heat Deflection temperature (HDT) and Vicat Softening Point (VSP).
Harness – Rockwell, Shore’ A, Shore’ D and for Metals - Vicker’s and Brenell’s.
Carbon Black Content and Glass filler content.
Flammability.
Calibration and Maintenance of Measuring and Monitoring Equipments.
Implementing Poke Yokes at high Severity areas.
Plastic Materials Handled – Nylon66, Nylon6, POM, TPU, PBT, PC, ABS, PS, SAN, PP, HDPE, LDPE, EVA, TPE & specialties like Glass, Talc Filled & master batches like UV treated & Abrasion resistance.
Material and grade Selection as per Customer Specifications and requirements.
Measuring Instrument Handled - Profile Projector, Tool Microscope & others
Gauges Handled - Pin Gauge, Slip gauge, feeler gauge, Radius gauge, Ring Gauge & others
Coordinating with CIPET for Special testing requirements and Updating ASTM, ISO, DIN, BS and BIS standards.
Handled Third Party Audits from BVQI and Audits from Railways

Accomplishments and Learning:
Initiated Internal Calibration of Verniers, Gauges and temperature Controllers by developing suitable Master Gauges and Master Instruments through NABL Accredited laboratories.
Implemented Poke Yokes in high severity areas.
Altered Process flow to minimize work and rejection – cost saving project.
Implemented SPC

Position Overview: Overall Responsible for Customer Interaction - Preparation and control of PPAP and other customer related documents, Control Plan Audit, In process Control, Dispatch control and Calibration Control. Part Validation & Testing of Plastic raw materials as per ASTM, DIN, ISO, and Railway Standards for all three units. Maintenance of QMS for all three Units
Major Operation: Injection Molding, Annealing, Printing, Assembly and Packaging
Reporting To: Chief Executive Officer

Professional training: Certified Six Sigma Green belt by Innovative Mindz Consultants Pvt. Ltd.
Trained on QMS ISO 9001:2008 internal Auditing and Certified.
Trained on EMS ISO 14001:2004 Internal Auditor and Certified.
Trained and certified on FMEA, conducted by Small piece Enterprises.
Certified LIFE SAVER – Fire prevention and fire fighting conducted by Crisis Management Pvt. Ltd.
New Product Development NPD team.
Problem solving Techniques.
QRQC

Professional Summary
Around 10+ years of Manufacturing Industry experience with expertise in Quality Assurance, Quality Control, NPI, Lean, SixSigma, General Management and People Development.

Hands on experience in development of Injection Moulding, Plating and Packaging. Expertise in tool development handling from FOT, Tool Capability, Machine Capability and Process Optimisation by DOE and ramping up to attain maximum Capacity.

With 7 engineers reporting to me and I am Excellent in People Management, Interpersonal skills, Decision making Involving Subordinates, Colleagues, Being a manager (People’s Manager), Facilitating Change, Team Building, Presentation Skills and People Influencing Skills with an Assertive and Positive attitude.

Awarded for the best operation team for reducing product complaint

Future Goals

Hard Work