Summary
Overview
Work History
Education
Skills
Languages
Accomplishments
Affiliations
Certification
Trainings
Timeline
Generic
Rajkumar Lokare

Rajkumar Lokare

Pune

Summary

As a seasoned professional in automotive manufacturing, I specialize in Customer Complaint Management, Plant Quality Leadership, Quality Assurance, and Supplier Quality Engineering. My expertise spans Strategic Sourcing, New Product Development, and QMS Implementation, with a strong emphasis on driving continuous improvement through Lean Six Sigma and the Theory of Constraints (TOC)

Customers Handled: Tata Motors, Mahindra, Ashok Leyland, Tata Cummins, Hyundai, JCB, Scania, Knorr-Bremse, VECV, John Deere, Escorts, Tata Hitachi, UD Trucks, Maan, Daimler, Volkswagen, Bajaj, Piaggio, etc.

Products Handled: Fuel, oil, and air filter assemblies and their components; oil/fuel filter modules; engine parts such as crankshafts and camshafts; vehicle body and chassis parts like front and rear axle beams; and vehicle interior components such as seating systems. Electronic parts such as PCBs, SMT processes, harnesses, and connector assemblies.

Processes Learned: Plastic and rubber molding, aluminum die casting, forging and machining processes, sheet metal press/stamping parts, surface treatment, and surface coating processes, as well as electronics part SMT and assembly processes.

Overview

17
17
years of professional experience
1
1
Certification

Work History

Deputy General Manager- Head of Quality

Uno Minda- Switch Division
Pune
11.2024 - Current
  • Drive end-to-end quality management and deploy improvement plans for customer awards.
  • Implement operational excellence and TPM; ensure compliance with IATF QMS.
  • Utilize problem-solving techniques (8D, QC Tools) while managing a team of 20+ engineers.
  • Coordinate with OEMs (preferably in the 2W segment) to establish and review quality procedures.
  • Plan and monitor QA operations, including budgeting and corrective actions.
  • Set rework and inspection standards; foster a quality-focused culture and performance improvement.
  • Develop and enforce in-process inspection/testing standards.
  • Compile and analyze quality reports to identify trends.
  • Manage supplier quality performance and provide expertise and support.
  • Create and deliver training modules to enhance team skills.
  • Address customer quality issues through direct interaction.
  • Conduct and review supplier and internal audits (IATF/MSM).
  • Deploy statistical tools for process stability and ensure calibration adherence.
  • Manage initial supply quality for new products post-SOP.
  • Oversee QMS implementation across plant processes and support ISO 14001/45001 compliance.
  • Ensure timely closure of non-conformities and lead quality activities from the HVPT stage.

Technical Director/Consultant

Global Engg Pvt Ltd.
Pune
05.2023 - 09.2024
  • Project Leadership: Oversee the execution of new projects, ensuring they stay on schedule and meet objectives.
  • Quality Assurance: Establish and uphold quality standards throughout the project lifecycle.
  • Daily Reviews: Conduct daily reviews to assess project progress, address challenges, and ensure alignment with quality goals.
  • Team Meetings: Facilitate regular meetings with cross-functional teams to promote collaboration and share updates.
  • Purchasing Activities: Oversee procurement processes to ensure timely acquisition of materials and components necessary for project success.
  • Progress Tracking: Monitor daily progress against project timelines and milestones, ensuring issues are addressed promptly.
  • Quality Reporting: Prepare and present daily and weekly quality reports to stakeholders, highlighting achievements and areas for improvement.
  • Risk Management: Identify potential technical risks and implement strategies to mitigate them.
  • Stakeholder Communication: Keep stakeholders informed about project status, quality metrics, and any significant changes.

Plant Quality Leader

Fleetguard Filters Pvt Ltd. (Cummins Group))
Pune
06.2011 - 04.2023
  • Plant Quality Management: Manage plant quality, including product manufacturing, customer satisfaction, warranty analysis, and supplier quality assurance. Handle PPAP clearance, new product development, and customer relationship management. Manage supplier selection and performance, lead warranty reduction projects, execute cost-effective automation, and supervise a team of 20 engineers and 50-60 inspectors.
  • Customer Relations and Quality Management: Act as the primary contact for customers, handling complaints, audits, PPAP, and warranty issues, and presenting process improvements. Key clients include Tata Motors, Cummins, Volvo, and others.
  • In-House Quality Management: Drive process improvements and enhance the QMS system. Implement poka-yokes and customer usage conditions on assembly lines. Participate in BPR meetings, manage new product development and customer PPAP, and execute low-cost automation projects. Oversee process, product, layout, dock audits, calibration, poka-yoke verification, SPC, MSA, and reliability testing.
  • Supplier Quality Management: Manage inspection of incoming parts, quality planning, and gauge availability. Drive supplier upgrades through audits and training, organize vendor meetings, monitor performance, handle PPAP, and conduct special process and annual audits.

Quality Engineer

Harita Seating Systems Ltd. (TVS-Group)
Pune
03.2010 - 04.2011
  • Lead a team of 3 executives and 15 inspectors, reporting to the Quality Head.
  • Plan and manage incoming, first off, in-process, and final inspections.
  • Analyze quality data, including supplier PPM, in-house rejections, rework PPM, and customer rejection PPM.
  • Apply problem-solving techniques using the 7 QC tools, Kaizen, 5S, and the 8D methodology.
  • Manage process, product, layout, and dock audits.
  • Handle PPAP for new parts at supplier end and resolve supplier quality issues.

Quality Engineer

Bharat Forge Ltd (Kalyani Group)
Pune
06.2007 - 02.2010
  • Lead a team of 3 executives and 6 quality inspectors, reporting to the Quality Manager.
  • Plan and manage incoming, first off, in-process, and final inspections.
  • Process knowledge of crankshaft manufacturing and heat treatment.
  • Operate CMM, Adcole, Counter graph, and air gauging units.
  • Track in-house and post-machining rejections.
  • Managed projects focused on reducing rejections and improving product quality.

Education

Diploma In Mechanical Engineering -

Government Polytechnic
Kolhapur
06-2007

HSC -

SVM
Kolhapur
06-2004

Skills

  • Plant Quality Management
  • Statistical process control
  • Change Control Management
  • Supplier quality management
  • Operational Excellence
  • Product and Process Validation
  • Customer complaint handling
  • Customer Audits, PPAP Handling
  • Continuous Improvement
  • Total Quality Management
  • Lean Six Sigma
  • Strategic sourcing, supplier audits
  • New Product Development
  • Theory of Constraints
  • Project Management
  • Problem solving: 8D, RCA
  • Warranty management
  • APQP, PPAP, SPC, MSA, FMEA
  • Negotiations and report writing
  • MS Office, Excel, Word, PowerPoint
  • Verbal and written communication
  • ERP Systems: SAP, Oracle, Windchill

Languages

Marathi
First Language
English
Advanced (C1)
C1
Hindi
Advanced (C1)
C1

Accomplishments

  • Received the QCFI Par Excellence Award for a quality improvement project in 2011.
  • Honored with the CMD Award from Cummins India in the Innovation Project category in 2014.
  • Recognized with the Best Supplier Award for zero customer complaints from Tata, JCB, and Hyundai.
  • Awarded Best Supplier for New Product Quality by TCL, Ashok Leyland, and VECV.
  • Supplier PPM was reduced from over 1000 PPM to below 100 PPM through MAFOI projects.

Affiliations

  • Received the MD Award from Fleetguard for contributions to QMS implementation, in-house controls, and PPAP of NPD parts for the new FFPL plant in Dharwad.
  • Implemented online and automated inspection systems to enhance reliability and capacity.
  • Improved supplier performance from 65% to 90% through EOL firewalls and process enhancements.

Certification

  • Qualified & Certified Internal Auditor for IATF16949:2016.
  • Qualified & Certified Internal Auditor ISO: 14001:2015.
  • Passed TOC Exam conducted by International Certification Organization.
  • VDA 6.3 Product Audit Standard

Trainings

  • APQP, PPAP, FMEA, MSA, SPC.
  • RCA, 8D Methodology, QC tools

Timeline

Deputy General Manager- Head of Quality

Uno Minda- Switch Division
11.2024 - Current

Technical Director/Consultant

Global Engg Pvt Ltd.
05.2023 - 09.2024

Plant Quality Leader

Fleetguard Filters Pvt Ltd. (Cummins Group))
06.2011 - 04.2023

Quality Engineer

Harita Seating Systems Ltd. (TVS-Group)
03.2010 - 04.2011

Quality Engineer

Bharat Forge Ltd (Kalyani Group)
06.2007 - 02.2010

Diploma In Mechanical Engineering -

Government Polytechnic

HSC -

SVM

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Rajkumar Lokare