Rajesh C
Chennai
Summary
Results-driven management professional with over 18+ years of experience leading high-performing teams and delivering measurable outcomes. Proven expertise in strategic planning, process improvement, and driving operational efficiency. Known for fostering a culture of accountability, collaboration, and continuous improvement. Highly adaptable, with a track record of meeting evolving organizational needs and exceeding performance goals.
Overview
18
18
years of professional experience
1
1
Certification
Work History
Manager- Supplier Quality
PCA Motors-Quess
Tiruvallur
03.2022 - Current
- Established material receipt date (MRD) during project kickoff, ensuring quality, quantity, and timing requirements.
- Executed part development using APQP methodology, completing each phase grid through PLM.
- Conducted official kickoff meetings with key suppliers and SQA, outlining essential project milestones.
- Performed NSA audits, periodic mass production audits, and progressive process audits as scheduled.
- Collaborated with suppliers to drive continuous improvement, reduce defects, and enhance productivity.
- Oversaw export quality for Latam region parts, including resourcing and tool refurbishment.
- Coordinated new part introduction with suppliers, ensuring timely completion of PCAT/PTR and PPAP.
- Implemented VAVE activities at suppliers and enacted corrective actions for issues arising in plant and Latam.
Deputy Manager-Quality Assurance
Royal Enfield
Oragadam
10.2014 - 02.2022
- Company Overview: A Unit of Eicher Motors.
- Responsible for sheet metal and fabrication, experienced in stamping process, spot and seam welding, MIG welding, and brazing process.
- Working for the new product/process development in-house, supplier products like frame (chassis), swing arm, and tank for Himalayan, Classic BS VI Twins, Meteor, and J1A by the APQP approach, and approving the same through PPAP.
- New source initial evaluation study for the joint venture between POLARIS, ENFIELD, and Vortex project.
- Developed strong relationships with stakeholders to facilitate smooth communication and project completion.
- Enhanced employee performance by providing regular feedback, coaching, and training opportunities.
- Design for manufacturability (DFM) study with the key suppliers and in-house product/process audit – finding gaps and improvement actions (Kaizen).
- For Frame / Fuel Tank – Periodic Audit – one process per month layered audit.
- Root cause analysis (RCA) for customer complaints of field return, vehicle assembly, paint shop, and in-process complaints, and taking the CA.
- Conducting a weekly quality review meeting with stakeholders.
- Conducting the PFMEA for the new projects and capturing the potential failure modes based on the past trouble data.
- Managing the team size of 7 engineers and 33 trainees, and reviewing KPIs.
- Process validation for the new process and approving the same before the SOP.
- Manage, coach, and develop a high-performing team that meets agreed objectives and delivers best practice results, added value, and continuous improvements.
- Knowledge of IMS ISO 9001, ISO 14000, and ISO 45000.
Senior Engineer-SQA / STA
Lear corporation India pvt ltd
Oragadam
07.2011 - 09.2014
- Company Overview: It's a Fortune 500 company. With headquarters in Southfield, Michigan, Lear maintains 221 locations in 36 countries around the globe and employs approximately 122,000 people. Here is a Tier 1 company supplying car seats to Renault Nissan India Private Ltd.
- Parts development: seat tracks, seat recliners, seat frames, seat trims, seat foams, and plastics from drawing to PPAP approval.
- Participation in a cross-functional team for the 'Supplier Selection' process to ensure that it is based on audit data.
- New product, periodic audit, consolidation, and following up on the corrective actions.
- Supplier change management control and ECN management control.
- Assisting and guiding the suppliers to make PPAP documents, verifying, validating, and approving the same.
- Monitor suppliers' PPM, track quality rejections through supplier scorecard systems, and drive suppliers to reduce the PPM while making the AOI to ensure all CTQs and their frequency are captured in their process.
- Prepare and maintain the TS documentation procedures, manuals, standards, and specifications.
- Review with the supplier's top management for the worst quality issues on a monthly basis.
- Creating the incoming standard and gauges during development.
- Conducting a PTR (Production Trial Run) at the supplier's end.
- Work with the program and purchasing for VAVE activities, and implement them at the supplier's end.
- Educating the suppliers on the requirements of gauges, fit, function, and approving the gauge and welding fixtures concept.
- Improved project efficiency by streamlining engineering processes and implementing innovative solutions.
- Monitored employee performance to keep projects on task.
Executive-Quality Assurance
IFB Automotive pvt ltd.
Bangalore
05.2010 - 07.2011
- Company Overview: It's an automotive sector of the IFB group (IFB home appliances, agro products, etc.). An ISO/TS 16949 and ISO 14001 company, manufacturing and supplying automobile accessories like seating systems, comprising seat recliners, seat sliders, height adjusters, and latches to Tier 1 suppliers of Maruti Suzuki India Limited, Mahindra & Mahindra, Tata Motors, Toyota, and Hyundai Motors India Ltd for various vehicle models.
- Conduct a daily rejection review meeting along with CFT members from Production, Process, and initiate necessary disposal actions, along with corrective and preventive actions through G8D.
- Planning for periodic inspection and testing.
- Making a corrective action report for the weekly top five process complaints.
- Attending to customer complaints and making 8D reports.
- Conduct process and product audits line by line on a monthly basis, and take corrective action for nonconformance.
- Preparing the process inspection procedure and standards.
- Conducting the monthly quality review for customer complaints and taking effective actions.
Engineer (QA)
Daebu Automotive Seat India Pvt. Ltd
Sriperumpathur
12.2006 - 04.2010
- Initiated and implemented process flow, FMEA, and control plans to align activities with design records.
- Executed New Product Development (NPD) following APQP methodology.
- Prepared bill of materials (BOM) while managing supplier documentation for approval.
- Conducted supplier assessments, evaluations, and audits to establish quality standards.
- Collaborated with suppliers to identify root causes of quality issues and developed corrective action plans.
- Performed internal audits as per established schedules to ensure compliance.
- Led weekly supplier presentations to communicate performance metrics and expectations.
- Managed a team of six, delegating tasks and motivating for timely completion of projects.
Education
B.E - Mechanical Engineering
Anna University
Chennai, TN04.2006
Skills
- APQP methodology
- PPAP compliance management
- Risk assessment through FMEA
- Continuous process improvement
- Lean Six Sigma black belt
- Experimental design (DOE)
- Design for manufacturability (DFM)
- Statistical process control (SPC)
- 8D problem solving
- Creative brainstorming
- Process variation reduction
- Error-proofing techniques (PY)
- GD&T
- CAPA
- Process validation
- Kaizen
- SGA: Small group activity
- Design approval process
- TS 16949 internal auditor
- New supplier assessment
- Product and process audit
- Identifying Critical to Quality (CTQ's)
- Problem-solving through 7 QC tools
- Risk management
- Data analysis
- Creating dashboards
- Weld quality evaluation
- Decision making
- Team leadership
- Documentation and reporting
- Cross-functional teamwork
- Contract management
- Supplier relationship management
- Multitasking
- Quick response, quality control
Certification
- Diamond Award, Achieved the prestigious Diamond Award, securing 1st place in the competition ABK/AOTS/QCFI
- Certificate of Appreciation, Certificate of appreciation for the outstanding contribution @ Stellantis, 03/24
- Lean Six Sigma Black Belt (ICBB), 10/21, 39703681
- TS 16949:2009 Internal Auditor, Nathan & Nathan, 2009
Accomplishments
- Received dual appreciation from IAP Head for exceptional quality problem-solving and line protection efforts, ranking #1 across IAP.
- Earned the prestigious Basalt Development & Launch Award from the Chief Engineer - Projects.
- Cost Savings Achievement: Earned 5-star rating for saving ₹25 lakhs by optimizing EVAP tube design, eliminating one operation, and resolving low-pressure complaints at Vehicle assembly.
- Received appreciation from Senior Vice President for field failure Frame (chassis) engine mounting crack issues resolved by correcting the mounting dimension in the fixture at supplier end.
- Reduced tank leak percentage from 1.8% to 0.8% through Design of Experiment (DOE) and re-validation.
- Successfully resolved in-process unsolved problems called latch fouling on the floor striker, recliner not locking, seat slow movement, etc.
Languages
- Tamil
- English
Timeline
Manager- Supplier Quality
PCA Motors-Quess
03.2022 - Current
Deputy Manager-Quality Assurance
Royal Enfield
10.2014 - 02.2022
Senior Engineer-SQA / STA
Lear corporation India pvt ltd
07.2011 - 09.2014
Executive-Quality Assurance
IFB Automotive pvt ltd.
05.2010 - 07.2011
Engineer (QA)
Daebu Automotive Seat India Pvt. Ltd
12.2006 - 04.2010
B.E - Mechanical Engineering
Anna University
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