Rahul Doliya
Supplier And Manufacturing Quality Engineer
Ahmedabad
Summary
Diligent, motivated, and passionate engineer with over 12 years of experience in the automotive industry, specializing in manufacturing and supplier quality engineering. Excels in challenging, collaborative environments with a strong focus on continuous improvement. Expertise includes managing customer complaints, overseeing program management, resolving quality issues, and conducting data analysis. Holds ISO 9001:2015 certification and Six Sigma Green Belt credentials. Demonstrated success in reducing warranty repairs for diesel engines by 45% year-over-year through targeted in-plant and supplier improvements, and played a strategic role in powertrain launches from concept to completion.
Overview
15
15
years of professional experience
Work History
Supplier Quality Engineer - Incoming Quality
Ford India Pvt. Ltd.
Ahmedabad
11.2019 - Current
- Lead current model quality improvement of suppliers (Q1, QR, R/1000, CPU), through Warranty Reduction, Bench marking, Lean Manufacturing, G8D at supplier sites.
- Analyse warranty and Customer Complaint specifically for VO plant.
- Establish ERA, ICA, PCA, and CAPA at the customer end to protect customers from issues.
- Provide technical guidance and training to the supplier for root cause analysis and actions.
- Attend an analysis of various customer complaints, taking corrective and preventive action through 8D report, DMAIC, 5D, Six Sigma, and 3 Leg 5 Why.
- Handling components, turbochargers, sensors, and base engine components like bearings, conrods, sheet metal parts, stamping parts, and machined parts.
- To Implement new process change and engineering change at Supplier end In Assy. Till PPAP approval and implementation.
- Drive closure of supplier process quality issues for warranty complaints and QRs. Conduct onsite evaluation visits for priority components and drive Special Attention Reviews with supplier management.
- Handaling sensor and Electical supplier, Specially Soldering and Brazing.
- Inspection for electrical components and Develop Implementation/Testing validation plan.
- Wiring Harness and Imported sensor Inspection/Testing and Handling.
- Lead QMS/QOS auditor (Product audit/Process audit)
- Provided technical assistance to suppliers in resolving complex manufacturing issues, improving overall product quality levels.
- Collaborated with cross-functional teams to identify potential supply chain risks and develop contingency plans accordingly.
Process and Manufacturing Quality Engineer - Engine Assy.
Ford India Pvt. Ltd.
Ahmedabad
03.2018 - 11.2019
- Lead engineer for launch and customer quality issues for power train sites.
- Evaluated new materials, tools, and equipment to determine suitability for use in the manufacturing process, ensuring optimal product quality levels were maintained consistently.
- Analyze customer issues from vehicle plant & warranty issues across the globe for powertrain products.
- Lead engineer for Issue management & data analysis for all customer complaints and have management reviews
- Responsible for Driving cross-functional teams like supplier quality, design, mfg. to overall reduce quality complaints by problem solving tools, prevent re-occurrence & horizontal deployment.
- Work towards warranty spend reduction by implementing a robust prevention and detection process. Product and Process audit.
- Key lead for DCP Review team.
- Lead for Change management for the Shop floor for Process Change.
- Monitor and Maintain Process capability for Key parameters for the Assembly.
- Attain & Analysis the customer complaint, taking corrective & preventive action through 8D report,DMAIC,5D
- Solving and Supporting TCF related issues and actions.
- Saved 0.7 million $ by implementing Continuous Improvement and lean manufacturing ideas.
- Improved customer satisfaction with timely resolution of product issues and thorough root cause analysis.
Process Quality and Launch Team Leader - Green Field Site Plant Launch
Ford India Pvt. Ltd.
Ahmedabad
09.2013 - 03.2018
- Quality lead for a global new petrol 1.5L engine launch & a diesel 2L turbo engine.
- Delivery of all programme deliverable for quality department on time.
- Responsible for process quality, final inspection & customer issues for both launches.
- Developing Extra Launch Quality initiatives & executing it for safe launch.
- Leading powertrain launch at customer sites by handling Voice of Customer Fleet drives durability issues analysis, address and contain all program issues and ensure concerns fixed before mass production builds.
- Capturing all issues at each launch builds and systemic driving for closure of all issues with a cross-functional team.
- Collect, deploy & validate the Lessons Learns from sister plants at launch phase of each program.
- Sign-off all assembly stations to ensure the process is performed to its engineering intent, error proofing checks & capability runs are met. IT systems validation.
- Develop PFMEA and drafting control Plans for each assembly line stations.
- Execute residual torque checks for all fasteners & develop control limits.
- PPAP documentation & sign-off
Diploma Engineer Trainee – Engine Central Quality (Trans Axle Assembly)
TATA Motors - Nano Plant Sanand (Gujarat).
Ahmedabad
08.2011 - 09.2013
- Responsible for improvement of Trans-axle line quality & sustenance.
- To sustenance line quality Conducting Process, Product audit, Millipore audit & step down audit.
- Responsible for Incoming gear quality through Gear roll testing.
- Conducting a daily morning meeting with operators & supplier representative.
- Attain and analyze the customer complaint, taking corrective and preventive action through NPST.
- Monitoring & analysis rejection, & daily disposal.
- Reduce machine breakdown and improve quality by using TPM. Improvement on trans axle line through Kaizen and Poke Yoke.
- Improvement at roll testing area & line through kaizens,5s & Poke yoke 10% rejection reduced.
- Participated in team meetings, providing valuable input on engineering strategies and offering suggestions for improvement based on knowledge gained during the trainee program.
- Reduced production costs through careful analysis of materials and manufacturing processes, recommending cost-effective alternatives.
Education
Bachelor of Technology - Mechanical Engineering
Silver Oak University
Ahmedabad01-2024
Diploma - Automobile engineering
Gujrat Technolaogical University
Gujarat01-2011
Higher Secondary School Certificate - undefined
Anand High School
Gujarat01-2008
Secondary School Certificate - undefined
M M High School
Sojitra, Gujarat01-2006
Skills
- Certified Six Sigma Green Belt
- Problem Solving(DMAIC, 8D 5Why,3Leg5Why)
- 7 QC tools
- FMEA,Control Plan Is Is not
- Effective Presentation & Communication
- Warranty Handaling
PPAP Support
- APQP
- Continuous Improvement
- Manufacturing processes
- Failure modes and effects analysis
- Process improvement
- Quality inspection techniques
- Quality documentation
Quality management system
Accomplishments
- Awarded for outstanding contribution in the Petrol engine program engine assembly, installation & commissioning activities in 2017.
- Certified for Six Sigma Green Belt on Timing cover t-joint oil seep & Oil pan leak projects in 2020 & 2021.
- Ford Internal Certified ISO auditor for ISO 9001:2015
- Recognized for powertrain support in successful launch in Ford Ranger vehicle in Asia pacific region.
- Executed Various assignments to VO.
- Save INR 4.4/ Engines by Various cost-saving changes Implementation in 2024
- Supplier QR trend reduced 20% with continuous improvement and SCAFF review with supplier partners.
Timeline
Supplier Quality Engineer - Incoming Quality
Ford India Pvt. Ltd.
11.2019 - Current
Process and Manufacturing Quality Engineer - Engine Assy.
Ford India Pvt. Ltd.
03.2018 - 11.2019
Process Quality and Launch Team Leader - Green Field Site Plant Launch
Ford India Pvt. Ltd.
09.2013 - 03.2018
Diploma Engineer Trainee – Engine Central Quality (Trans Axle Assembly)
TATA Motors - Nano Plant Sanand (Gujarat).
08.2011 - 09.2013
Higher Secondary School Certificate - undefined
Anand High School
Secondary School Certificate - undefined
M M High School
Bachelor of Technology - Mechanical Engineering
Silver Oak University
Diploma - Automobile engineering
Gujrat Technolaogical University