Prakash Kothalkar
Pune
Summary
Development and Quality Management Professional with 10 years of experience in New Product Development (NPD), Quality, Process Quality, Field Quality, and Supplier Audits across Godrej Appliances, Haier, and Western Refrigeration. Proven ability to embed quality into product development using Stage-Gate/Toll Gate processes, ensuring robust design validation, risk management, and cross-functional collaboration (R&D, Manufacturing, Supply Chain, Service, and Marketing). Skilled in digital NPD reporting, cost analysis, and variance evaluation, with a track record of supporting ₹110 Cr+ cost optimization projects, and leading multiple product launches.
Overview
10
10
years of professional experience
1
1
Certification
Work History
Manager – Development & Field Quality
Godrej Appliances Ltd.
Pune
08.2021 - Current
- Directed development, quality planning for nine new model launches, and fifty-plus SKUs, embedding validation testing into the Stage-Gate process.
- Collaborated with R&D, Operations, Supply Chain, and Service teams to resolve technical issues and accelerate NPD execution.
- Designed and led digital NPD quality trackers, linking field complaints with design, process improvements, and cost-saving initiatives.
- Oversaw Homa CKD Project (China): cabinet foaming, door foaming, refrigerator assembly, quality inspection, serviceability, and Indian imports.
- Supported ₹110 Cr+ cost optimization projects with BCG, validating and approving product/process changes from a quality perspective.
- Conducted economic analysis and variance reviews, delivering savings through brazing rod optimization (₹2.7 Cr), gas leakage project (₹20 Lakh), and liner thickness reduction (₹1.2 Cr).
- Represented projects in review meetings, managed priorities, negotiated resources, and escalated issues as required.
- Mentored 6 engineers and 22 executives, building competency matrices, training plans, and succession pipelines.
Quality Lead – Development & Process Quality
Haier Appliances India Pvt. Ltd.
Pune
02.2019 - 07.2021
- Coordinated development quality activities for refrigerator production, ensuring compliance with scope, budget, and quality targets.
- Led process audits and PFMEA updates, boosting FTR by 22%.
- Conducted field failure analysis with service teams, reducing repeat complaints by 18%.
- Drove supplier CAPA closure, ensuring robust process adherence.
Engineer – Development & Outgoing Quality
Western Refrigeration Pvt. Ltd. (Hoshizaki Group Company)
Pune
08.2015 - 01.2019
- Managed development validation checks and final outgoing quality control for commercial refrigerators.
- Implemented drop and shipping tests, reducing logistics damages by 15%.
- Developed a digital defect classification to strengthen complaint analytics.
- Coordinated supplier CAPA closures and introduced operator training, improving inspection accuracy by 20%.
Education
B.E. -
Mechanical Engineering
Amravati05-2015
Diploma -
Mechanical Engineering
Akola05-2012
Skills
- New product development
- Stage-gate processes
- Advanced product quality planning
- Production part approval process
- Process failure mode effects analysis
- Project management
- Scope and budget management
- Timeline and risk management
- Digital reporting for NPD
- Cross-functional leadership
- Research and development
- Manufacturing and supply chain
- Service and marketing integration
- Product validation and testing
- Performance and safety testing
- Reliability and drop testing
- High ambient and economic analysis
- Cost and variance evaluation
- Savings initiatives
- Continuous improvement methodologies
- Kaizen and Six Sigma principles
- Zero defect strategies
- Statistical process control techniques
- Poka-yoke implementation
- Team leadership and training
- Mentorship programs
Certification
- ISO 9001:2015 lead auditor – quality management system
- ISO 14001:2015 lead auditor – environmental management system
- ISO 45001:2018 Lead Auditor – Occupational Health and Safety Management System
- ISO 50001:2018 lead auditor – energy management system
- Six Sigma Green Belt certified
- Certified IMS internal auditor
Accomplishments
- Launched 9 refrigerator models and 50+ SKUs through full validation
- Delivered ₹2.7 Cr, ₹1.2 Cr, and ₹1.67 Cr savings via structured cost innovation
- Executed 108 CI projects across design, supplier process, and in-house layouts
- Designed Bump and Jolt Testing Jig, reducing logistics damage by 25%
- Reduced FCR by 35% with a Six Sigma project on gas leakage
Languages
Marathi
First Language
Hindi
Proficient (C2)
C2
English
Proficient (C2)
C2
Timeline
Manager – Development & Field Quality
Godrej Appliances Ltd.
08.2021 - Current
Quality Lead – Development & Process Quality
Haier Appliances India Pvt. Ltd.
02.2019 - 07.2021
Engineer – Development & Outgoing Quality
Western Refrigeration Pvt. Ltd. (Hoshizaki Group Company)
08.2015 - 01.2019
B.E. -
Mechanical Engineering
Diploma -
Mechanical Engineering
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