M Dharani Devi

• Responsible for overseeing the end-to-end process flow of locomotive valves, DV, GE valves, and HLV
• Developed tools, fixtures, and gauges in line with the production requirements
• Prepared and released Assembly Instruction Standards (AIS) for all valves and new products
• Implemented relayout and line balancing strategies to optimize the process flow and enhance line efficiency
• Successfully achieved PQCDMS targets within the given timeframe
• Implemented capacity enhancements to remove bottlenecks and attain the desired production volume
• Initiated continuous improvement initiatives using LEAN manufacturing, VSM, and MOST techniques
• Proactively resolved customer site requirements on a periodic basis
• Conducted DRC analysis and PCR impact analysis to address and improve process issues
• Collaborated with the Cross-Functional Team (CFT) to prepare PFMEA and ensure process compliance with RPN ranking
• Acted as the M3 key user for PED, responsible for creating and updating routings, MBOM, and part numbers, conducting negative inventory analysis, and addressing discrepancies in inventory management.
• Monitored daily operations and ensured compliance with company policies and regulations.
• Coordinated with other departments to ensure smooth functioning of activities.
• Created processes for handling customer complaints effectively.
• Identified cost-saving opportunities that helped reduce expenses significantly.
• Ensured adherence to safety measures at workplace as per regulatory guidelines.
• Change management coordinator and ensured analysis completion within 30 days.
• Managed overall budgeting process including forecasting expenditures.

• As the Lead of the Quality Department in 2W EV projects, managed Supplier Quality, Incoming quality, Line Quality, and Product Quality.
• Established quality and reliability standards based on customer requirements and defined the necessary metrics to assess performance against these standards.
• Actively focused on reducing PPMs (Parts Per Million), Cost of Quality, in-house scrap, and waste.
• Collaborated with the Operations team, worked closely to prevent non-conformities, customer complaints, and rework.
• Development and management of the Quality Management System (QMS). Updated procedures as required and conducted training for the team members.
• Presented relevant Key Performance Indicators (KPIs) to senior management. This helped in providing visibility into the quality performance and identifying areas for improvement.
• Played a key role in resource planning and developing the organizational structure.
• Additionally, prepared and managed the annual Quality budget, ensuring the successful completion of projects within budgetary constraints.

• Conducted day-to-day inspection and clearance of parts related to Railway cabinets and electrical harnesses
• Identified and eliminated waste to enhance operational efficiency
• Took the lead in initiating QRQC processes and resolving customer Non-Conformance Reports (NCRs)
• Prepared self-inspection check sheets
• Implemented lean manufacturing practices
• Actively participated in CR and ECN meetings
• Ensured the successful implementation of CRs
• Analyzed and resolved red tags efficiently
• Conducted 8D analysis and arrived at effective solutions for critical customer defects.
• Analyzed customer feedback and complaints to identify areas of improvement in the quality management system.
• Identified root causes of nonconformity issues, developed corrective action plans, monitored progress, and reported results.
• Evaluated process capabilities to determine conformance with specifications.
• Performed failure mode effects analysis to predict potential problems before they occur.
• Updated documentation for rejected components and finished products.

KEY ACHIEVEMENTS

E Loco projects (Govt of India project)

• Reduced inspection time for cabinets from 5 hours to 3.5 hours by employing the QCP approach in 3 phases.
• Implemented digitalized configuration tracking using barcode and QR code technology, resulting in a reduction of 2 hours in manufacturing time and 0.8 hours in inspection time.
• Designed and developed an application using Microsoft Powerapps to capture customer NCRs and internal complaints, creating a comprehensive library for final inspection assistance.
• Developed an ISPC (In Station Process Control) approach to capture control points, escape areas, and perform Statistical Process Control (SPC) RFT.
• Tracking & Monitoring of Method time Vs Spent time for all products to find deviations

• Led end-to-end process planning for various components in motorcycle assembly
• Reviewed and signed off PPAP, TPDR, and FPDR documents through APQP approach.
• Collaborated with the R&D team during the design phase to incorporate design feedback in terms of fit and finish, GD&T, and DFA at various stages of product development.
• Implemented material flow planning and optimization strategies resulting in a significant reduction in cycle time.
• Prepared PFC, PFMEA, Control plan, DFB, and DAP documents, Also PPAP preparation & getting approved.
• Developed and implemented effective false-proofing methods
• Implemented QC story approach and ensure quality standards

KEY ACHIEVEMENTS

BMW G310R (INTERNATIONAL BUSINESS)

• Improved the process capability index of steering fastener tightening from 2 to 10 by using DC tool and optimising the process.
• First time usage of Automated guided vehicle (AGV) for assembly rather than conventional conveyors.
• Auto grease application process planning and proving for front fork assembly.
• Design and development of fixtures with PU pads for style (plastic) parts assembly thereby reducing scratches on sensitive parts.
• Improvement of QZF/ QZS quality scores by optimising manufacturing process.
• Manufacturing cost reduction by providing peristaltic pumps to apply Loctite in critical joints.
• Relayout of plastic parts assembly cell thereby making it flexible for all 3 models hence reducing floor space and ease manufacturing process.
• Usage of vision system to ensure chassis VIN marking and cup pressing, upload date to server for online tracking.

TVS APACHE RR310 (DOMESTIC BUSINESS)

• Implementation of electronic tool for crimping of fuel tank and generate barcode thereby avoiding missing and double crimping operation.
• In Design phase, optimised fit & finish across 2 models and changed drawing with respect to DFA.
• Periodic monitoring of KPI (Key performance indices) to ensure all manufacturing and quality parameters are in line with the spec without any deviation over time period.

ROLE IN PED - FACILTIY PLANNING ENGINEER

• End to end process planning for Crankcase and cylinder head assembly using fasteners and rubber seals.
• Preparation of PFC, PFMEA, Control plan & PPAP using APQP approach.
• Improve efficiency (yield) of workstation by reducing cycle time and standardise the process
• Conduct process capability study and ensure manufacturing process parameters are in spec over period of time.
• Conduct MSA study for Gauges and tools that support manufacturing process.

KEY ACHIEVEMENTS

COMMUTER MOTORCYCLE SEGMENT (STAR CITY+)

• Improved the process capability index of cylinder head tightening from 1 to 5 by using DC tool and optimising the process.
• Increased the yield of engine assembly process from 600/ shift to 800/shift by line balancing and additional tools planning.
• Combining cylinder head pressing and leak testing thereby reducing manpower (reduction of manufacturing cost).
• Elimination of white smoke problem in vehicle by QC story approach.
• Drained oil contamination reduction by introducing washing machine for all A class, B class and C class parts in engine assembly.
• First time POC of Crankcase induction heating process to ease assembly without damage to crankcase bore.

Executive Motorcycle segment (Victor Refresh)

• Executed Zero defect cell for cylinder head assembly using automation.
• Selection of vendors and price negotiations for manufacturing facilities of victor model.
• Prepare and sign off of RFQ, Equipment note, DAP and ensure receipt and commissioning of facility.
• Production trial run to ensure maximum productivity and quality of manufacturing process.
• Auto screw feeding and robot tightening mechanism implementation.