Hi, I’m
Dhineshkumar S
Quality Assurance Engineer
Salem,TN
Summary
Quality Engineer with proven experience in automotive and electronics manufacturing, specializing in
customer complaint handling, process audits, defect reduction, and data-driven quality improvements.
Skilled in 8D, RCA, 7 QC Tools, FMEA, PPAP, and trend analysis. Strong technical and analytical
ability to improve product reliability and process stability.
Overview
3
years of professional experience
Work History
Tata Electronics
Lead Reliability Engineer
05.2025 - Current
Job overview
- Conducted failure analysis and Root Cause Analysis (RCA) on in-house components using the 8D/Why-Why methodology, supported by background and historical failure data, enabling data-driven corrective and preventive actions (CAPA), and reducing the overall failure rate.
- Operated and managed Universal Testing Machines (UTM) for reliability, durability, and mechanical validation tests in line with OEM and customer standards.
- Applied basic test programming and parameter setup to ensure repeatable and compliant reliability test execution.
- Maintained, calibrated, and validated test fixtures and jigs, ensuring measurement accuracy, repeatability, and compliance with quality standards.
- Implemented Kaizen and continuous improvement initiatives in laboratory and testing areas to improve cycle time, safety, and process efficiency, aligned with the Tata standards.
- Developed, reviewed, and enforced Standard Operating Procedures (SOPs) for quality testing and lab operations, ensuring adherence to OEM quality requirements.
- Collaborated with cross-functional teams (Manufacturing, Design, Supplier Quality) to support issue containment, validation, and production readiness.
Hitachi Astemo
Quality Assurance Engineer
03.2022 - 12.2023
Job overview
- Performed customer complaint and warranty part analysis on automotive electronic components, evaluating functional, dimensional, and performance parameters, contributing to a 20–30% reduction in repeat customer complaints.
- Led and supported 8D problem-solving activities, identifying root causes, implementing CAPA, and monitoring effectiveness, achieving on-time closure for over 95% of customer complaints.
- Implemented containment actions at the assembly line and customer end, helping to prevent defect escape and stabilize quality within 24–48 hours of issue detection.
- Conducted structured root cause analysis (RCA) using quality tools, supporting a 15–25% reduction in internal defect recurrence.
- Coordinated with OEM customers to implement corrective actions, maintaining 100% compliance with customer communication and response timelines.
- Executed functional and performance testing of coils, improving test pass consistency and repeatability across production batches.
- Performed line audits to verify corrective action effectiveness and Poka-Yoke implementation, contributing to a 10–20% reduction in line rejections.
- Analyzed line NG, rejection, and rework parts, supporting initiatives that reduced scrap and rework trends month-on-month.
- Conducted Poisson distribution tests to assess visual inspection capability, followed by operator training, resulting in improved defect detection consistency.
- Ensured accurate capture and analysis of End-of-Line (EOL) test data for all models, enabling early detection of performance drift, and proactive corrective actions.
- Carried out daily Gemba patrol audits, reducing operator-related deviations and process abnormalities.
- Conducted product and process audits, supporting process stability and audit compliance with zero major nonconformities during internal reviews.
- Monitored and analyzed product and process performance data, identifying improvement opportunities that contributed to continuous quality improvement initiatives.
- Investigated customer complaints and internal non-conformances, ensuring systematic closure and recurrence prevention.
- Operated X-ray inspection systems to verify internal coil construction, improving hidden defect detection capability.
- Analyzed and interpreted quality and manufacturing data to identify failure trends and systemic root causes, supporting fact-based decision-making.
- Prepared inspection standards and control documents as per customer-specific and OEM requirements, ensuring consistent inspection execution.
- Reviewed production and inspection records for accuracy, traceability, and compliance, supporting 100% audit readiness.
- Collaborated with cross-functional teams to implement process and system improvements, contributing to measurable quality performance improvements.
- Performed internal audits, risk assessments, and process walkthroughs in alignment with IATF 16949, supporting successful audit outcomes.
Delphi - TVS Technologies Limited
Quality Trainee
05.2021 - 02.2022
Job overview
- Verified and ensured the quality of fuel pumps manufactured in the plant by conducting in-process and final quality inspections, and prepared quality reports for supervisors and the production manager.
- Performed in-process quality assurance (IPQA) checks on child parts and final assemblies, ensuring compliance with drawing specifications, control plans, and quality standards.
- Assisted in root cause analysis (RCA) for in-process defects, and supported the implementation of corrective actions.
- Maintained inspection records and quality documentation, ensuring traceability and audit readiness.
- Supported process audits and daily line checks, contributing to stable process performance and reduced rework.
- Ensured adherence to 5S and safety practices within the quality inspection areas.
Education
K.S.Rangaswamy College of TechnologyTiruchengode, India
Bachelor of Engineering from Mechatronics
04.2001
University Overview
- Final Grade: [Number] 74%
S.R.V Boys Hr.Sec SchoolNamakkal, India
High School Diploma
04.2001
University Overview
- Final Grade: [Number] 65.3%
Skills
8D/RCA ( OEM Standards)
Cp/Cpk, MSA, SPC
Customer Complaint Handling
Defect Mode Reduction
PPAP, APQP, PFMEA
Line/Process/Product Audit
SOP, Traceability, Poka-Yoke
7QC Tools
Key Projects
- Defect Reduction Project – Hitachi Astemo
Reduced coil NG rates by analyzing defect clusters and deploying targeted corrective actions. - Reliability SOP Standardization – Tata Electronics
Unified reliability testing procedures to improve customer audit readiness. - Inspection Optimization
Strengthened visual inspection standards, reducing operator errors.
Timeline
Lead Reliability Engineer
Tata Electronics
05.2025 - Current
Quality Assurance Engineer
Hitachi Astemo
03.2022 - 12.2023
Quality Trainee
Delphi - TVS Technologies Limited
05.2021 - 02.2022
K.S.Rangaswamy College of Technology
Bachelor of Engineering from Mechatronics
04.2001
S.R.V Boys Hr.Sec School
High School Diploma
04.2001