M Shyam Kumar

Major Customers: Bajaj Auto Ltd, Royal Enfield, M&M, TVS, Hero Motors, Suzuki Motors, Renault Nissan, Daimler Commercial Vehicles

PRODUCTS:

EV - Telematics Unit, DCDC Converters, Accelerator Position Sensors, Traction Motor, Motor Controller Units

Non EV - ECU, Instrument Clusters, Control Switches, Starter Motor & Magneto, Lightings

• Leading Customer Quality Function across 6 Manufacturing Plants for major customer Bajaj Auto Ltd, under Electrical Business Units
• Focused on EV products warranty issues analysis and CAPA to ensure customer satisfaction
• Monitor Warranty performance for Electrical Business Units and drive COPQ reduction projects through CFT approach
• Recover Warranty debit Cost from vendors due to quality issues in supplied products
• Prepare Monthly Data on Warranty Quality Performance for Operations Review by Top management
• Assisted in recruiting, hiring and training of team members
• Providing Technical guidance and Training to Teams members and Engineers to improve capability and competency for problem solving
• Observed each employee's individual strengths and initiated mentoring program to improve areas of weakness

PRODUCTS

Motorcycles: JAWA (Classic and 42), YEZDI (Roadster, Scrambler, Adventure)

· Supplier assessment audit, selection, and approval

· Review Design releases for Proto, Tooling and Mass production

· Ensure New Product Development products met SOR and customer requirements

· Technical support during application study, vehicle builds, process and product validation

· Supplier APQP Process approval through PPAP and PSW sign-off

· Quality Planning through TGR, TGW and Horizontal deployment of actions

· Warranty RPT and In-house PPM reduction in current products

PRODUCTS

Motorcycles: Classic, Bullet, Interceptor 650, GT 650, Himalayan, Thunderbird

SQA - NPD

· Review and approve Design releases for Proto, Tooling and PPAP

· Define Quality requirements and standards for Process and Product at all development phases

· Ensure ‘Customer Specific Requirements’ are understood and met by Vendor

· Provide Technical support to Vendor process in sample builds, tests, and inspections

· Ensure development samples meet Quality requirements

· Initiate and lead Part application studies with Supplier, Design and Testing team

· Provide Technical support in part storage, handling, assembly process for Vehicle Builds

· Approve and improvise vendor manufacturing and assembly processes throughout development

· Develop Product and Process quality based on Vehicle builds fit & functional feedback

· Technical support & co-ordination in analysis, actions for Engine and Vehicle validation issues

· Conduct PPAP Audit and sign-off warranty

· Ensure Product Quality and take necessary action with suppliers for Non-Conformance in SOP

SQA - WARRANTY

· Responsible in taking appropriate actions for FFFIR (Field Failure First Investigation Report) Parts

· Monitor and analyze warranty complaints from DMS (Dealer Management System)

· Identify top Electrical Parts contributing major warranty claim

· Classify and prioritize actions based on criteria as safety, fault frequency, function, and cost

· Joint Analyze with Dealer to understand customer voice for critical failures

· Joint analyzes of warranty return parts and take appropriate actions at vendor

· Provide Technical support in educating dealers for preliminary actions at customer complaints

· Co-ordinate with CFT for corrective action implementation

· Track, monitor, prepare and communicate warranty trend to identified top vendors

Major Customers: TVS, Maruti Suzuki, Tata Motors, M&M, Renault Nissan, Honda

PRODUCTS: Gear Reduction Starter, Internal fan Alternator, Ignition Coils for Passenger Car Segments

· Prepare Production Part Approval Process (PPAP) for new launch projects to customers

· Review and update process control documents and ensure it adhere with set requirements

· Prepare, update process and product check sheets, inspection standards, visual control charts

· Prepare limit samples, master samples to validate Process, Poka-Yoke, and Test rigs

· Conduct Internal Process audits and Product audits as per TS 16949 Standards

· Analyze quality performance using statistical and analytical tools and methods

· Identify failure mode in manufacturing and assembly processes and take immediate actions

· Expertise in Root Cause Analysis of internal production line failures and take corrective actions

· Warranty and Customer complaint analysis, take corrective actions and 8D preparation

· Conduct simulation trials to reproduce failure for confirmation on root cause

· Improve process quality through implementing new ideas on SMED, optimizing change over

· Training new employees according to standard operating procedures

Major Customers: ILJIN Automotive, ELGI Compressors

PRODUCTS – Brake Drums, Air Compressor Pistons, Torque Plate

· Inspect and Qualify receipt, in-process, FG parts as per quality standards

· Direct product testing and approval throughout production process