ATUL H. ZALA
Kamrej
Summary
Quality and production executive with over 8 years of experience in automotive manufacturing, focusing on paint shop quality control and process auditing. Demonstrated expertise in root cause analysis and driving continuous improvement initiatives. Skilled in both robotic and manual paint inspection, defect identification, and ensuring compliance with quality standards. Proven track record of cross-functional collaboration to implement corrective actions that enhance product quality and reduce waste.
Overview
9
9
years of professional experience
1
1
Certification
Work History
Senior Executive – Quality
Suzuki Motor Gujarat Pvt. Ltd.
03.2023 - 10.2024
- Ensured painted vehicle bodies adhered to Suzuki's global quality standards through continuous process validation and audit.
- Conducted layered audits, surface defect analysis, and implemented PDCA cycle for sustained improvements.
- Spearheaded initiatives that reduced topcoat paint defects by using root cause analysis (5 Whys, Fishbone) and cross-functional actions.
- Maintained documentation and traceability as per IATF 16949 and ISO 9001 quality systems.
- Actively collaborated with production, engineering, and maintenance teams to uphold zero-defect delivery goals.
Junior Engineer – Paint Shop (Topcoat & Primer)
MG Motor India Pvt. Ltd.
04.2019 - 02.2023
- Monitored daily booth operations with focus on First Time Quality (FTQ) and SPQRC targets.
- Led troubleshooting of manual and robotic paint defects; optimized process parameters for new models.
- Trained team members on SOP adherence, poka-yoke techniques, and quality checkpoints.
- Oversaw Paint Mix Room: managed stock levels, developed new shades, and ensured correct paint formulation.
- Initiated cost-reduction Kaizens, achieving 12% cost savings in consumables and thinner usage.
Team Leader – Paint Shop (Topcoat)
Tata Motors Ltd.
Sanand
01.2018 - 04.2019
- Handled shift-wise Topcoat operations including DURR robot spray settings, startup checks, and maintenance.
- Ensured continuous compliance to paint quality standards through defect mapping and process standardization.
- Prepared real-time production quality reports and conducted weekly quality performance reviews.
Diploma Engineer Trainee – Paint Shop (PTED & Topcoat)
Tata Motors Ltd.
Sanand
01.2016 - 01.2018
- Managed PTED Line operations, monitored bath health, and coordinated filter replacements and tank checks.
- Gained practical exposure in electro-deposition coating, sanding process, and surface preparation.
- Assisted in new equipment trials and validation of PTED parameters to meet model-specific standards.
Education
Diploma - Mechanical Engineering
Bhagwan Mahavir Polytechnic
SuratSecondary School Certificate (SSC) -
Sarvodaya Vidyalaya
SuratSkills
Paint Shop Quality & Process Control
- Automotive Paint Quality Control
- Robotic Paint Application
- Color Management & Mixing
- Surface Defect Analysis
- Line Quality Control
- Paint Defect Troubleshooting
- Process Auditing & Inspection
- Root Cause Analysis & CAPA
- Data Collection & Reporting
Quality Systems & Standards
- ISO 9001 Compliance & IATF 16949 Standards
- SOP Development & Standardization
- Visual Control Systems & Poka-Yoke Techniques
- 5S Methodology
Continuous Improvement & Collaboration
- Lean Manufacturing Practices
- Core Quality Assurance Principles
- Cross-Functional Collaboration
- Supplier Quality Management
Certification
- Basic Operation and Programming of DURR Robotic Systems
- World-Class Quality Training – Tata Motors
- MG Production System – Quality Frameworks
- Quality Circle Participation & Improvement Workshops
Accomplishments
- Reduced Dust Count by 20% through spray booth airflow improvement and filter management.
- Successfully launched new shade formulations with zero initial customer complaints.
- Led DURR Robot health monitoring & predictive maintenance project, increasing uptime by 18%.
- Contributed to 10% cost reduction in Dual-Tone Painting via material savings and process optimization.
- Implemented robust quality gate systems ensuring Right-First-Time (RFT) outputs across shifts.
Languages
- English (Fluent)
- Hindi (Fluent)
- Gujarati (Native)
Disclaimer
I hereby declare that the above information is true to the best of my knowledge and belief.
Timeline
Senior Executive – Quality
Suzuki Motor Gujarat Pvt. Ltd.
03.2023 - 10.2024
Junior Engineer – Paint Shop (Topcoat & Primer)
MG Motor India Pvt. Ltd.
04.2019 - 02.2023
Team Leader – Paint Shop (Topcoat)
Tata Motors Ltd.
01.2018 - 04.2019
Diploma Engineer Trainee – Paint Shop (PTED & Topcoat)
Tata Motors Ltd.
01.2016 - 01.2018
Diploma - Mechanical Engineering
Bhagwan Mahavir Polytechnic
Secondary School Certificate (SSC) -
Sarvodaya Vidyalaya
Similar Profiles
Vikas PatelVikas Patel
Dashboard Assembly - IP Line (Assembly Shop) at Suzuki Motor Gujarat Pvt. Ltd.Dashboard Assembly - IP Line (Assembly Shop) at Suzuki Motor Gujarat Pvt. Ltd.
Gaurav ChoudharyGaurav Choudhary
HR Executive at Suzuki Motor Gujarat Pvt. Ltd.HR Executive at Suzuki Motor Gujarat Pvt. Ltd.
Shivjee YadavShivjee Yadav
Senior Executive at Suzuki Motor GujaratSenior Executive at Suzuki Motor Gujarat
Nilesh VekariyaNilesh Vekariya
Field Sales Officer at ANABH GEMS PVT.LTDField Sales Officer at ANABH GEMS PVT.LTD
Amol DesaiAmol Desai
Senior Executive Quality and Research at Loreal Research and InnovationSenior Executive Quality and Research at Loreal Research and Innovation