Ajay Kumar
Haridwar
Summary
With over 11 years of experience in highly competitive and dynamic environments, I possess a strong expertise in strategic planning and implementation, coupled with excellent communication skills. I have successfully managed and mentored cross-functional, matrix teams across various assignments, demonstrating a well-organised, self-motivated, and creative approach to achieving corporate goals. My technical exposure spans injection moulding, compression moulding, epoxy, compounding, and pultrusion, with a focus on the automobile and electrical industries. I hold certifications in Six Sigma (Green, Yellow, and Black Belt) and am an internal auditor for IATF16949:2016, ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, and ISO/IEC 17025:2017. My expertise includes advanced quality management skills such as APQP, PPAP, PFMEA, MSA, SPC, TPM, and a variety of problem-solving and continuous improvement methodologies.
Overview
11
11
years of professional experience
1
1
Certification
Work History
Dupty Mnage Quality Assurance
Legrand India Ltd.
Haridwar
12.2024 - Current
- Develop, implement, and maintain the QMS (e.g., ISO 9001 : 2015, ISO14001 :2015,ISO45001:2018).
- Ensure compliance with industry standards like IEC, UL, BIS
- Lead internal and external audits (e.g., ISO, customer audits).
- Oversee inspection and testing of electrical switchgear, control panels, and components.
- Ensure all products meet design specifications, electrical safety standards, and performance criteria.
- Approve or reject raw materials and final products.
- Monitor manufacturing processes to ensure consistent quality.
- Use Six Sigma, Lean, or Kaizen tools for continuous improvement.
- Conduct root cause analysis and implement corrective/preventive actions (CAPA)
- Evaluate and audit suppliers for compliance with technical and quality standards.
- Establish incoming inspection criteria for electrical components (breakers, relays, contactors, Plastic Assyebly Parts etc.).
- Manage non-conforming materials from suppliers.
- Lead the quality control team and inspectors.
- Provide training to staff on quality procedures, standards, and tools.
- Foster a quality-oriented culture across departments (engineering, production, procurement).
- Maintain accurate records of inspections, test results, deviations, and corrective actions.
- Prepare quality reports and metrics (e.g., First Pass Yield, Defect Rates, NCRs).
- Ensure traceability of components and manufacturing history.
- Handle customer complaints and returns (RMA process).
- Work with regulatory bodies, and ensure compliance with relevant standards.
- Represent the company during customer quality reviews or audits.
Deputy Manager Quality Assurance & NPD
Powercam Electrical Pvt. Ltd.
Bahadurgarh
11.2022 - Current
- Ensured quality assurance processes were followed to ensure maximum product quality
- Developed a comprehensive quality assurance program that ensured all deliverables met the highest standards of quality
- Preparation and submission of Production Part Approval Process (PPAP) documents to establish robust process and product control.
- Active participation in the documentation and implementation of ISO 9001:2015,IATF 16949:2016 ISO14001:2015,ISO45001:2018,ISO/IEC17025:2017 standards.
- Achieved significant reductions in Customer rejection PPM and internal PPM through the application of Quality Control tools such as Pareto Analysis, 5-Why Analysis, and Cause & Effect Diagrams.
- Ensured compliance with Quality Management Systems (QMS) by conducting regular QMS audits and implementing Corrective Action Preventive Action (CAPA) and Opportunities for Improvement (OFI) closures.
- Led customer audits for renowned companies like Rinder(UNO Minda),Neolight ZKW, TGC (The Gund Company), Schneider Electric, Siemens, Suzlon Energy, L&T, Delta, Eaton Electric, Emerson, ABB, ensuring full implementation of system changes as per customer requirements.
- Oversaw Vendor Upgradation activities, coordinating monthly reviews with the Powercam team to drive supplier improvements.
- Managed Total Productive Maintenance (TPM) initiatives, improving operational efficiency and minimizing downtime.
- Led in-process and supplier quality activities, focusing on optimizing internal processes and supplier performance to enhance product quality.
- Led 5S, Safety, and Kaizen activities to promote a culture of continuous improvement and operational safety within the plant.
- Conducted systematic analysis of process data related to rejections, rework, and wastage to reduce the cost of poor quality(COPQ) and improve overall efficiency.
- Maintained and controlled all quality system documentation and records, ensuring full compliance with established standards.
- Managed activities related to minimizing the 7 Wastes as part of Lean Manufacturing practices, contributing to process optimization and cost savings.
Assistant Manager QA
Meenakshi Polymer Pvt. Ltd
Neemrana
12.2021 - 10.2022
- Maintenance of Quality Management Systems (QMS) across the organization, ensuring compliance with IATF 16949:2016, ISO 14001:2015, and ISO 45001:2018 certifications.
- Managed Customer Audits (System, Process, and PPAP Audits), ensuring timely resolution of non-conformances (NC) and submission of 8D Reports for corrective actions.
- Successfully handled recertification and surveillance audits for IATF 16949:2016, ISO 9001:2015, ISO 14001:2015, and ISO 45001:2018 standards, achieving positive audit outcomes.
- Spearheaded the PPAP, APQP, and FMEA processes during new product development, ensuring comprehensive quality planning and risk mitigation.
- Collected and presented Management Review Meeting (MRM) data to top management on a half-yearly/yearly basis, facilitating strategic decision-making.
- Managed calibration and validation of measuring devices as per the audit plan, ensuring accuracy in measurement systems.
- Led Product, Process, and Dock Audits, ensuring product conformance to customer and regulatory requirements.
- Coordinated external lab testing as required, ensuring product compliance with standards.
- Monitored and displayed quality indicators on the shop floor, driving continuous improvement initiatives on a weekly and monthly basis.
- Conducted process capability studies on machines to optimize operational performance.
- Verified first piece and last piece inspections, ensuring production quality consistency.
Senior Engineer QA
Machino Plastics Ltd.
Manesar
08.2018 - 11.2021
- Ensured full compliance with QMS through regular QMS audits, closure of Opportunities for Improvement (OFI), and implementation of Corrective Action Preventive Action (CAPA).
- Conducted process and product audits at regular intervals as per schedule, following up on action plans to ensure continuous improvement and adherence to quality standards.
- Performed defect analysis to identify and resolve quality issues, implementing corrective measures for continuous improvement.
- Managed Total Productive Maintenance (TPM) initiatives to improve equipment effectiveness and minimize downtime.
- Supervised 5S, Safety, and Kaizen activities within the plant, fostering a culture of continuous improvement and operational safety.
- Analyzed process data related to rejections, rework, and process wastage, implementing strategies to reduce the cost of poor quality and optimize operations.
- Managed the documentation and control of all records required for Quality System implementation, ensuring compliance with IATF 16949:2016 and ISO 9001:2015 standards.
Engineer QA
Alpha Maier Pvt. Ltd.
Manesar
04.2017 - 08.2018
- Oversaw Process Setup Approval to ensure alignment with production standards and customer requirements.
- Conducted New Development Tool Trials and Sample Inspections for new product introductions, ensuring proper functionality and quality.
- Led Daily Red Bin Analysis and maintained Rejection Entry Records to identify root causes and drive corrective actions.
- Developed and maintained Work Instructions for the use of inspection instruments, ensuring consistent and accurate measurements.
- Managed the Final Inspection of molded and painted parts, ensuring adherence to IATF 16949:2016 and customer quality standards.
- Compiled and analyzed Daily MIS Reports for the molding and paint shop to monitor production performance and quality metrics.
- Provided 5S and Safety Training to operators and inspectors, promoting a culture of workplace safety and continuous improvement.
Diploma Engineer Trainee
Rinder India Pvt. Ltd.(UNO Minda Group)
Bahadurgarh
05.2014 - 03.2017
- Operated and optimized injection molding machines, ensuring adherence to production standards and minimizing defects.
- Maintained and updated process-related documentation in compliance with ISO/TS 16949 and ISO 14001 standards.
- Implemented Standard Operating Procedures (SOPs) and enforced quality standards to meet stringent automotive industry requirements.
- Conducted root cause analysis using 7 QC Tools (Pareto, Cause & Effect, etc.) to resolve production issues and improve process efficiency.
- Led the preparation of Production Part Approval Process (PPAP) documents to ensure product and process validation for OEM clients.
- Drove 5S Implementation across production lines, improving workplace organization and enhancing operational efficiency.
Education
Bachelor of Technology-Pursuing - Mechanical Engineering
Maharishi Dayanand University
Rohatk08-2024
Short Term Course -
CIPET
Murthal, Sonipat11.2016
Diploma - Plastic Technology
Chhotu Ram Polytechnic College
Rohtak05.2014
Skills
- Lean Six Sigma Black Belt
- ISO9001 : 2015
- IATF16949 : 2016
- ISO14001 : 2015
- ISO45001 : 2018
- ISO/IEC 17025 : 2017
- Core Tools (APQP, PPAP, PFMEA, MSA, SPC)
- 7 QC Tools
- VSA (Vendor System Audit)
- Kaizen improvement and poka-yoke
- 8D
- A3
- CAPA
- Calibration & Validation
- BIS,IEC,UL
Certification
- Lean Six Sigma (YB,GB,BB), Noida, 02/01/24, 06/01/24
- ISO9001:2015 Internal Auditor, Quality Austria, Noida, 01/01/23, 01/01/23
- IATF16949:2016 Internal Auditor, Quality Austria, Noida, 08/01/23, 08/01/23
- ISO14001:2015 Internal Auditor, Quality Austria & Vexil Business, Noida, 01/01/23, 01/01/23
- ISO45001:2018 Internal Auditor, Vixil Business, Delhi, 03/01/21, 03/01/21
- ISO/IEC17025:2017 Laboratory System & Internal Auditor, QCI, Delhi, 03/01/24, 03/01/24
Personal Information
Date of Birth: 05/17/96
Timeline
Dupty Mnage Quality Assurance
Legrand India Ltd.
12.2024 - Current
Deputy Manager Quality Assurance & NPD
Powercam Electrical Pvt. Ltd.
11.2022 - Current
Assistant Manager QA
Meenakshi Polymer Pvt. Ltd
12.2021 - 10.2022
Senior Engineer QA
Machino Plastics Ltd.
08.2018 - 11.2021
Engineer QA
Alpha Maier Pvt. Ltd.
04.2017 - 08.2018
Diploma Engineer Trainee
Rinder India Pvt. Ltd.(UNO Minda Group)
05.2014 - 03.2017
Bachelor of Technology-Pursuing - Mechanical Engineering
Maharishi Dayanand University
Short Term Course -
CIPET
Diploma - Plastic Technology
Chhotu Ram Polytechnic College
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