THANGARAJ DHANAPAL
Coimbatore
Summary
Senior Engineer - Quality Assurance improving precision gear quality through prototype evaluation, measurement-system validation, and supplier component approval. Programs and optimizes GINA 2D and 3D routines on Klingelnberg P65, P100, and P150 machines while applying PPAP, MSA, Gauge R&R, 8D, FMEA, SPC, and APQP to resolve issues and prevent recurrence. Strengthens inspection throughput, team capability, and ISO 9001:2015 compliance across gear inspection, Nital etching, MPI, and final inspection.
Overview
3
3
Languages
4
4
Certifications
17
17
years of professional experience
Work History
Senior Engineer - Quality Assurance
ZF Wind Power Coimbatore Pvt. Ltd.
08.2011 - Current
- Evaluate 14+ prototype gearbox components against drawings, dimensional specifications, and quality requirements with Production and Engineering.
- Optimize GINA 2D and 3D measurement routines for Klingelnberg P65, P100, and P150 gear systems, including master validation and Hofler cross-verification.
- Lead root cause investigations and corrective actions for product, process, measurement-system, and customer quality concerns using 8D, MSA, Gauge R&R, Process FMEA, and CTQ.
- Drive Lean and continuous-improvement initiatives through process mapping and capability studies, contributing to a 30% improvement in throughput while maintaining customer quality requirements.
- Oversee multi-functional quality control operations across gear inspection, Nital etching, MPI, and final inspection while balancing manpower, competency, machine capacity, and priorities.
- Develop skill matrices, assess competency gaps, and coach team members to build multi-skilling across 34 team members and improve operational flexibility.
- Control COPQ and inspection capacity by tracking machine utilization, workload, lead time, and bottlenecks, then qualify suppliers, coordinate ECN implementation, and support ISO 9001:2015, APQP, internal audit management, component cleanliness audits, AMC activities, P-machine troubleshooting, and P150 installation and commissioning.
Diploma Trainee
Wheels India Limited
02.2010 - 07.2011
- Inspected 5-10 sample and new-development components daily using arm-type CMM and FARO GAGE CMM.
- Developed practical programming knowledge on FARO GAGE CMM while supporting inspection of new-development components.
- Built quality plans for new products and applied APQP, PPAP, and Process FMEA disciplines during launch support.
- Supported TPM activities, 5S training, implementation, and audits while reinforcing lean manufacturing practices on the floor.
Contract Technician
Indian Space Research Organisation (ISRO)
07.2009 - 01.2010
- Maintain accurate activity logs while supporting scientists and engineers with test preparation and results tracking.
- Process 2 specimens per shift during materials testing using Thermomechanical Analyzer Q400 and Dynamic Mechanical Analyzer Q800.
- Conducted material-property testing with Thermomechanical Analyzer Q400 and Dynamic Mechanical Analyzer Q800.
- Prepared specimens for analysis and maintained detailed activity logs for scientist and engineer review.
- Provided technical support to scientists and engineers throughout testing and reporting activities.
- Documented test observations clearly to support analysis, validation, and follow-up discussions.
- Supported laboratory workflow by keeping specimen handling, testing, and recordkeeping organized across assignments.
Education
Bachelor of Engineering - Mechanical Engineering
Coimbatore Institute of Technology
Coimbatore, Tamil Nadu12-2023
Diploma - Mechanical Engineering
Government Polytechnic College
Krishnagiri, Tamil Nadu04-2009
Skills
- PPAP
- MSA
- Gauge R&R
- SPC
- 8D
- APQP
- Internal audit management
- CTQ
- Process FMEA
- Root cause analysis
- Process capability
- Lean manufacturing
- Supplier quality management
- Customer complaint handling
- Measurement system analysis
- Process validation
Accomplishments
- Improved throughput by 30% through process mapping and capability studies while maintaining customer quality requirements.
- Pioneered an automated visual inspection solution for grinding-burn detection, minimizing manual intervention and enhancing defect-detection consistency and reliability.
- Designed shaft lifting equipment to reduce loading time and improve material handling.
- Automated gear-data processing through Excel VBA and introduced a queuing model for capacity utilization.
- Implemented digital inspection reporting on the EIQMI terminal and digitized final inspection check sheets and traceability.
- Introduced a truing method to reduce gear inspection time and developed technical training materials and video content on gear burns.
Certification
ISO 14001 Environmental Management System - Internal Auditor
Timeline
Senior Engineer - Quality Assurance
ZF Wind Power Coimbatore Pvt. Ltd.
08.2011 - Current
Diploma Trainee
Wheels India Limited
02.2010 - 07.2011
Contract Technician
Indian Space Research Organisation (ISRO)
07.2009 - 01.2010
Diploma - Mechanical Engineering
Government Polytechnic College
Bachelor of Engineering - Mechanical Engineering
Coimbatore Institute of Technology