Senthilkumar Sankarasubbu

Experience

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  Honeywell

  Jan 2007 - Dec 2010

  Executive Quality Assurance

  • Carrying out Final product audit on the SKUs before being shipped to export market. Creation of Visual Aids for all the SKUs being assembled. Corporate Dashboard coordinator. Testing of ERP Applications - Delivery, Quality, Warranty modules. Developing requirement specifications for QM module • Internal Auditor – ISO 9001:2008; OHSAS. Interpreting the supplier defects encountered at assembly to the supplier and liaising with suppliers for the closure of the defects. Standardization of Packaging. Fixation of organizational targets for Customer PPM, Supplier PPM, Manufacturing PPM, COPQ etc.• Utilizing Six-Sigma Tools to solve quality related issues and focusing on continuous improvements and poke yoke methods for elimination of Product escapes. Identify quantitative and qualitative data to develop and enhance employee skills. Tackle problems in logical ways and brainstorm solutions.• Conduct quality assurance reviews on ability to deliver, risk levels, financials, contractual adherence, timeliness etc.Establish and maintain a quality assurance review schedule in accordance with policies. Document and implement quality management system, and to ensure effective implementation, monitoring and control of quality management system at manufacturing , packing, testing and warehouse activities with respect to laid down procedures, systems and identify areas for improvement. Show less

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  TVS

  Dec 2010 - Apr 2013

  Manufacturing Quality Engineer

  • Control plan adherence. Rejection analysis. Reduction of CLRs, ALRs, MLRs. Handling of customer complaints. Creation of CAPA for customer complaints. QMS adherence. New product development. Establishment of EOL -End of Line Testing. Creation of Work Instructions. Performing Gauge R&R• Build an effective project management and quality assurance processes and standards in line with the company’s corporate program delivery framework. Establishes raw material standards by studying manufacturing and engineering requirements, negotiating with suppliers, devising testing procedures• Establishes product quality documentation system by writing and updating quality assurance procedures.Prepares product and process quality reports by collecting, analysing and summarizing information and trends.Develop processes to review accumulated audit findings and Develop proposals to address the issues and concerns identified from the audits Show less

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  FORVIA HELLA

  Jun 2013 - Mar 2020

  Deputy Manager

  • Functioned as a Project Quality Lead (Quality planner) in the Development of VW POLO Headlamps– throughout the PEP phases(Kickoff to SOP & launch support).Created and executed the design validations for the headlamps, raw materials, single parts based on the customer requirement standards• Identification of significant characteristics for the headlamps.Creation of measuring concept and established Lamp measuring techniques for verification of lamps.Moderation and coordination for creation of PPAP documents such as DFMEA, PFMEA, Control plan, process flow, Gauge R&R etc.Responsible for closure of supplier ISIRs. Carried out analysis of field failures of the headlamps and implemented the changes in design & process. Project: Modular LED System – Signal functions | Customer: Daimler, Ford, General Motors | Jan 2018 • The Signal functions such as Day time running light,Turn Indicator, Spot lamps etc are developed by a special project team (MLS team) based on customer specific requirements. Thus developed Modular LED systems are integrated into the Headlamps. Working as a Lead QD in the MLS project team • Involved in the project team for design and development of the customized signal function modules which includes PCBAs, Heat Sinks and Interfacing Brackets.Review of the drawings before release. Preparation of Test instructions for the Signal function Modules. Moderation of DFMEA Show less

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  Varroc Safety and Mobility

  Nov 2020 - Aug 2021

  Project Quality Manager

  • Project Quality manager - leading a complete program like headlamps (multi variants, combo lamps, reflex, chmsl, etc with a set of quality planners under my supervision. Acting as Direct Interface with the OEMs for the Technical Negotiations. Defining the Quality budget for the smooth Execution • Successfully achieved the K0 – Final PPAP release from the customer . Lead two complete programs Nissan Magnite and Renault Kiger including the Healdamp variants ,Tail lamps and DTRL lamps .Implemented the Annealing Process for Cover lens with appropriate validations and successful go ahead from the customer .• Creation and Sign off of cardinal Quality Agreements with the customer. Coordinating the PPAP sign off with the customer. Directing the ECNs for averting the Quality Pitfalls post launch. Currently leading 2 big Programs – Nissan Magnite Program – 3 Variant Headlamps , RR , Combo Lamps & DTRL• Build ideation and defect prevention processes within the team and share insights that help fix the broken/bad processes. Track such insights to closure by working closely with concerned teams. Lead the development and implementation of Total Quality Management/Risk Management frameworks• Scheduling and overseeing governance meetings with all partners on performance, process Show less

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  Expleo Technologies

  Aug 2021 - Apr 2022

  Project Quality Manager

  Responsible for complete Project Quality Management for select Vehicle Exteriors.Commodities : Headlamps , Rear Lamps, DRLs , Internal Lightings . Making sure the Vendors delivers to the Project Milestones of the Vehicle build . Responsible for the System and Quality deliverables are adhered in the Program Responsible for the Final Approval of the Project release for smooth supplies to the Vehicle build .Creation of DVPaR for Stand alone Headlamps and also Vehicle Integrated Headlamp Testings Responsible for the PLM Updation for the Electrical commodity suppliers.Validation and approval of the Testing Budgets provided by the Vendors Validating the Changes driven by the Vehicle project team & Responsible for the Implementation of ECRs(Changes) in the Electrical Commodity . Supplier Liaison for Budget, Time line fixation for the implementation of the Vehicle ECRs . Responsible for the PPAP Sign off for the Electrical Commodity in liaison with Vehicle Quality Team and Project Quality Team . Carrying out the Process Audits and ensuring the Audit findings are implemented at the Vendor Location . Ensuring Vehicle level team complaints on the Electrical Commodities are addressed to and corrective actions are implemented . Follow up with the supplier for closure of the Industrialization Implementations . Validation Process Capability studies , OTOP Runs , Tool validations for the complete program Vendor Handled : Ms.NeoliteZKW Lightings , Bahadurgarh Ms.Electrica Engineering private limitedCommodities Handled : Headlamps,Tail Lamps , DRLs,CHMSL etc. Show less

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  Maswer Automotive India Pvt. Ltd

  Apr 2022 - Apr 2023

  Lead Auditor -VDA 6.3

  Carrying out Comprehensive Audit on the Vendors against the VDA 6.3 Requirements P1 to P7 Performing Potential Analysis audit based on VDA 6.3 Requirements Carrying out PPAP Audits in line with Customer specific requirements Performing Capacity Assessment on behalf of the OEMs and chalking out improvement plan to the Tier1 and Tier 2 for capacity adherence and capacity enhancement inline with OEM requirements Performing Follow up audit for verification and closure of the original audit Non conformances . Carrying out Audits based on IATF 1649:2016 requirements .More than 100 Audit Man days and 25 Vendors have been Audited during this tenure.Adept in chalking out Audit plan & Executing for automotive organizations . Show less

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  M&R Manufacturing Sdn. Bhd.

  Apr 2023 - Dec 2023

  QA Manager

  Leading multiple Quality Functions including Manufacturing Quality, NPI Quality and QMS functions .Leading a team of Continuous experiment experts and responsible for continuous experiment activities implementation in the plant.Leading the a combination of 40 team members under various facets of quality Ensuring the ISO 9001:2015 requirements are adhered The product portfolio includes fabrication parts with tolerance ranging as less as 30 Microns and are to be fitted to the semi conductor industries.Handling of Customer complaints Responsible for the skill development of quality team members according to the facets they are handling. Show less