NEERAJ KUMAR

Zero Km Customer Handling

• For my individual Products, Responsible for handling customer complaints & New Product Development of Suzuki Motor Gujrat, TATA Motors, for Customer line rejection (PPM & Non-PPM Relevant) and Warranty received parts and provide the analysis report to the customer with all action details by using tools like 8D methodology, Pictorial Why~Why, and A3 Report.
• Responsible for conducting customer audits/Visits on the shop floor and follow-up with CFT for NC point closer.
• Responsible for Monthly data preparation like monthly customer rejection (CLR, Warranty), customer portal report, FPY trend & Pareto analysis, NQE (Internal & external), Audits along with action summary and present the same with management.
• Manage the Customer complaint/Analysis/testing activities of Electronics Product:- infotainment systems, Microphone systems, Speaker systems , Telematics systems, PCB Manufacturing, SOC , IOC Microcontroller analysis, Circuit schematics, CRO, Multimeters

Customer Warranty Management:-

• Warranty claims analysis: Investigating and resolving warranty claims, determining root causes, and implementing corrective actions.
• Warranty policy and procedure development: Developing and maintaining warranty policies and procedures.
• Warranty data analysis: Analyzing warranty data to identify trends, patterns, and areas for improvement.
• Communication with stakeholders: Communicating with customers, dealers, and internal teams regarding warranty issues and resolutions.
• Continuous improvement: Identifying and implementing opportunities for continuous improvement in warranty processes and product quality.

Project Leading/NPD activities :-

• Applying business transformation practices such as Program Management, VA/VE in programs to improve the processes and production
• Working and communicating effectively with cross functional team members in the the various departments sitting globally in the organization
• Manage end to end infotainment system programs delivery, requiring both applications and development engineering.
• Ensure SW development processes, integration, and release of software as per program milestone Ensure Hardware & Mechanical development process is executed as program development milestones
• Closely track product qualification during program development and ensure on time completion of EV, DV& PV qualification and incorporate lessons learnt after every qualification tests.
• Development review with internal & external CFT for NPD/ECN/PCR parts.
• As per the customer requirement or bench marking Development for New projects through APQP methodology with support of sourcing team.

Process/SQA Activities:-

• Analysis of the daily basis process rejections of SMT & Assy. testing line and maintaining the record of Root cause & actions details in QRQC (Quick Response Quality Control) Format.
• Responsible for the Monitoring all Process and Every Machines Parameter at SMT, Throughole, ICT, Functional Testing. Prepare and Analysis the in-house Rejection data as Per daily Basis.
• Verify all Critical Spec. and Parameter of every Machine and testing parameter that weather it is as per Control plan and as per process Requirement or not
• Control the Supplier rejection, Analysis of Daily Process Rejection PPM at Throughole Line and SMT etc. and Monitor all Process from Incoming to Final Dispatch of Product.
• Monitoring Process to analysis Defect via Trend graph and 7QC like (PARETO GRAPH, Check Sheet, ISHIKAWA DIAGRAM….) tools or using Why-2 Analysis with proper Countermeasure as well as Corrective and preventive action for Non-conformance Product.

Job Profile :-

• Coordinated As a CFT team members from in process quality for in house and customer problem analyses
• Analysis of Quality Problem & systematic corrective actions with the help of 8-D, Why, Why , 5W1H analysis methodology for Customer complaint, Vendor / Supplier End and in house.
• Representing Quality Department as an audited during surveillance audits, re-certification audits by external certification body for QMS verification.
• In house certify Auditor, on site assessment and evaluation of in house’s capability and quality system, evaluation of product sample, Product performance
• Preservation & Review of all QMS Documents like Quality Manual, Quality procedure, Quality documents, formats, records & methods in line with latest CSR (Customer Specific requirements) & as per ISO/TS 16949:2009 Standard
• Good exposure in Improvement continual improvement methodologies like, 5S, Kaizen, Poka yoke.
• Good Exposure in problem solving technique like, 7QC Tool, 8D, 5W1H, Why why analysis and etc.
• Monitoring & Calibration of all type requirement instruments as per annual calibration plan.
• Handling and monitoring of supplier though supplier rejection, supplier action, supplier rating, supplier audit as per plan and etc.
• Conduct the salt spray testing as per plan and customer requirements.
• Knowledge of All Quality Instrument ( Vernier caliper , Height Gauge , Micro Meter , Hardness testing Machine , Bore Gauge , All Standard gauge ), profile projector
• Knowledge of all Quality Parameters such like of ( Quality Check sheet and , Inspection standard , Knowledge of 7 Qc Tools and 6 Sigma Tolls
• Monitoring & Documentation for PPAP submission.
• Monitoring lead time for each customer complaint replies against the set targets and defective part analysis along with CFT team.
• Horizontal deployment of corrective actions for the impact on other similar processes.
• Carry out Machine Capability and Process Capability study & to improve capability indices based on results.
• Conducting daily scrap analysis with Mfg. Team, planning ensure proper disposal of Non Conformities.
• As a process owner co-ordinate Outgoing Product Quality Audit (Dock Audit) and safeguard outgoing quality by direct action.
• Verifying all Processes (Customer Orientated, Management Orientated & Support Processes) of Quality Management system for their Effectiveness and Efficiency in line with ISO/TS 16949 requirements through Internal Audit, Manufacturing specific Process Audit, and Product Audit.
• Analyze Internal and External Failure quality cost – Ensure and Verify Time bound corrective / Preventive actions.
• Control & monitoring of in process inspection, final inspection & pre dispatch inspection as per Quality Inspection Plan.
• Follow up the NC close and action taken against internal system audit, external audit, customer audit as per requirements of ISO / TS 16949 & ISO 14001 with support of other departments.
• Compile internal system audit & External audit report and give feed back to Top Management.
• Knowledge of 5 ‘S’ and also conduct of 5 ‘S” Audit as per scheduled. Working in continues improvement project Like Kaizen.

Job Profile :-

1. Quality Planning: - Develop and implement quality plans, procedures, and standards for cluster and speed sensor products. - Collaborate with design, development, and manufacturing teams to ensure quality requirements are met.

2. Process Control and Improvement: - Implement and monitor quality control processes, including inspection, testing, and validation. - Identify and address process failures, implementing corrective actions and preventive measures. - Drive continuous improvement initiatives, using tools like Six Sigma, Lean, and Root Cause Analysis.

3. Product Quality: - Conduct product testing, validation, and certification, ensuring compliance with industry standards (e.g., ISO 26262, SAE J1211). - Investigate and resolve product quality issues, working with cross-functional teams to implement corrective actions.

4. Supplier Quality Management: - Evaluate and qualify suppliers, ensuring they meet quality and performance standards. - Monitor supplier performance, conducting audits and implementing corrective actions as needed. 5. Quality Documentation and Reporting: - Maintain accurate quality records, including test reports, inspection results, and certification documents. - Prepare and present quality reports to management and customers, as required

Job Profile :-

1. Quality Planning and Development: - Develop and implement quality plans, procedures, and standards for cold forging and steering suspension components - Collaborate with cross-functional teams to identify and mitigate risks

2. Process Control and Improvement: - Implement and monitor quality control processes, including inspection, testing, and validation - Identify and address process failures, implementing corrective actions and preventive measures - Drive continuous improvement initiatives, using tools like Six Sigma, Lean, and Root Cause Analysis

3. Product Quality and Reliability: - Ensure product quality and reliability through testing, validation, and certification - Conduct root cause analysis and implement corrective actions for defects and failures

4. Supply Chain Quality Management: - Evaluate and qualify suppliers based on quality and performance standards - Monitor supplier performance and implement corrective actions as needed

5. Quality Documentation and Reporting: - Maintain accurate quality records, including test reports, inspection results, and certification documents - Prepare and present quality reports to management and customers, as required