SANGAIAH C
Product Fatigue Testing & Strain Measurement in Air Suspension System
Mogappair East
Summary
Dynamic professional with over 24 years of experience in manufacturing operations, quality assurance, and R&D testing and validation. Recognized for exceptional communication and relationship management skills, complemented by strong analytical, problem-solving, and organizational capabilities. Proven expertise in managing cross-functional activities related to purchased items, fixture development, and fabricated parts while effectively coordinating with vendors to enhance process operations and meet stringent requirements. Adept at driving process improvements and quality initiatives through resource planning, in-process inspections, and collaboration with internal departments, utilizing advanced quality techniques such as 7 QC Tools, APQP, PPAP, PFMEA, Quality Control Plans, 8D Analysis, and CAPA.
Overview
24
24
years of professional experience
10
10
Certifications
2
2
Languages
Work History
Assistant Manager – R&D Test Center
Wheels India Limited
02.2020 - Current
- Presently associated with Air Suspension Division - R&D - Test Centre, Wheels India Limited, Chennai as Assistant Manager. With roles involving engineering activities along with team building with design & other cross functional teams. Along with this quality compliance & audit, co-ordination with internal departments for new product development, Implementation of Lean Manufacturing, Safety & ESG, Product testing & validation are part of my roles & responsibilities
- Testing Activity consists of Material Incoming Register & Tested Parts identification, Inspection Report Follow-up
- Pre-Testing Activity comprising of, Verification of Test Request, Verification of Tested Parts Inspection Report, Check Available of Testing Fixture & Actuators, Test Setup Inspection, Write Test Program, Implementation of WI, SOP & OPL along with its review and Review & Continuous Improvement on the same.
- Perform the Post Testing Activities like Report Preparation, Load Vs Displacement Curve Preparation & Stiffness Calculation and, Scrap the Tested Parts As per Tested Parts Retention Period Work Instruction and Failure Analysis Preparation & Report Collection
- Strain Gauge measurement & Correlation with FEA results
- Lean Tools implementation
- Implementation for ISO 17025
- Identification New Standards & Test Conditions (ASTM, ASM, AIS, & CMVR)
- Safety Auditing consists of observing Near Miss Closure, S.O. Points Closure, Create & Audit MOC, Work Permit & Monthly MRM Presentation to carried out.
- Working in EMS Auditing which consists of Air Leak Audit Points closure, Water Consumption Points Closure, Carbon Foot Print Study - LCA - Life Cycle Assessment & ESG - Environment Social Governance.
- February 2020 to Till Now, (5 Years & Still)
Assistant Manager – Manufacturing & Quality
Wheels India Limited
12.2014 - 01.2020
- Performing shop floor control review through hourly, shift, daily and weekly monitoring of the production. Monitoring production run to make sure that, it stays on schedule and correct any problems that may arise along with monitoring product standards and implementing quality control check sheets, to make sure the finished product meets a certain level of quality. Involving new product development.
- Responsibility Daily production and achieve as per plan
- Control production process non-conformities
- Main responsibility for achieve the productivity with using Available Resource.
- SOP implementation with Methods team
- Proficiently achieved zero down line rejection and process rejection by using Six sigma Methodology.
- Re-Established the Welding process parameter (Arc & Resistance welding) through process qualification and re validation method.
- Skilled at planning work, making decisions. Exposure to Why-Why Analysis for any Manufacturing, Incoming, Warranty problems, Customer complaints Quality problems.
- Organize OJT and Job rotation of shop floor employees
- Work to improve OEE / SMED / MUDA elimination / Autonomous maintenance and shop floor improvement
- Activities like 5S, QCC, Idea generation, workplace safety etc.
- Ensure to achieve the department KPI target every month
- Monitor and control cost and usage of consumables
- December 2014 to January 2020, (5 Years & 2 Months)
- Supervised day-to-day operations to meet performance, quality and service expectations.
- Improved customer satisfaction by addressing and resolving complaints promptly.
- Developed strong working relationships with staff, fostering a positive work environment.
- Collaborated with the management team to develop strategic plans for business growth and improvement.
- Implemented staff training programs, enhancing product knowledge and improving customer service skills.
Senior Engineer - Manufacturing
Wheels India Limited
07.2010 - 11.2014
- Day to day problem solving in production line (MIG & Resistance welding, Press shop and Final machining operations). For validate the welding process do the destructive testing. Administering the inventory and controlling the cost. Identifying areas of obstruction/ breakdowns and taking steps to rectify the equipment through application of troubleshooting tools.
- Responsibility Daily production and achieve as per plan
- Control production process non-conformities
- Main responsibility for achieve the productivity with using Avl. Resource.
- Daily interacting with Quality for resolve the Nom-conformities & Maintenance teams for reduce the down time.
- Ensuring preventive maintenance as per plan for bottling equipment’s
- Responsible for the Kaizen activities of the organization, improvement idea collection.
- Optimizing resources and obtaining maximum quality output
- Ensuring that health and safety guidelines are followed in the plant
- Maintain harmony and discipline in the shop floor
- Co-ordinate with Project team to implement new project trials and SOP
- Efficiently improved the method and imparted training to the Operators.
- Controlled shop floor through 8 supervisors and 53 operators along with cost saving through suggestions and Improvements through TPM, QCC
- Managed a team of 60 people; assigning those tasks, and motivating them to meet deadlines.
- Hands on experience in process planning, single piece process flow, layout planning and line balancing.
- Facilitator for TPM and QCC projects for operators initiating group and for identify Poke yoke’s and implementing productivity techniques.
- Project leader and better knowledge in Lean Manufacturing techniques.
- July 2010 to November 2014, (4 Years & 5 Months)
Engineer - Quality Assurance
Wheels India Limited
05.2004 - 06.2010
- Carry out the audits like process audit, product audit, Dock audit, Supplier audits, Customer’s Audit and Familiarized with inspections like layout, patrol, first off, last off inspection. Managing the incoming Quality Assurance, TQM, TPM, In-Process Quality Assurance, Final Quality Assurance, customers’ complaint and customers’ audit. Upgrading the vendors by vendor audit, developing systems at vendor end and vendor rating. Implementing steps for curtailing product / process rejections and defects. Reducing cost of poor quality. Monitoring adherence to quality systems and complying with various quality standards.
- In charge for Quality Assurance functions & Co-ordinator for QMS.
- Audits (Process, Product and Dock Audits)
- Responsible for In process quality control like press shop & Axle assembly shop quality activities.
- Maintaining QA Records
- Handling customer complaints, Take corrective action and check effectiveness of action.
- Follow and record the CFT
- Development and Implementation of Quality Management System
- Preparing of PFD, CP, PFMEA, PPAP Doc for new product.
- Customer rating monitoring through customer feedback & take action
- Corrective and preventive action of in housing Quality problem
- Organizing for daily meeting with all the concerned manufacturing, tool room, maintenance & methods for reviewing the quality issues and getting action plan for taking corrective actions for the issues.
- Follow the Axle weld sample and shear testing approval
- Receiving Inspection of all Components
- Daily Red bin Analysis with CFT & initiate action
- Daily Defect Recording analysis of defects during production & Assembly, Corrective action initiation for process defects
- Monitoring and measurement of products
- Preparation of work Instruction along with process Engineer.
- Continuous improvement activities along with team members
- Ensure PDI of all parts before Dispatch as per check sheet, Report & take Counter measure for defects.
- Preparing inspection methodologies, visual displays for OK, NOT OK samples in each process in shop floor like press shop and assembly shop
- May 2004 to June 2010, (6 Year & 1 Months)
- Maximized team productivity through continuous improvement initiatives and implementation of best practices in QA methodologies.
- Reduced defect rates by designing and executing comprehensive test plans and test cases.
- Conducted root cause analysis for defects, leading to targeted improvements in the production process.
- Increased product reliability by performing thorough regression testing on each release cycle.
- Assisted in training new QA engineers, providing guidance on best practices and company-specific procedures.
Trainee & Apprentice
Delphi-TVS
02.2002 - 12.2003
- Responsible for Achieving the Production target.
- Assisting for Set-up Time reduction
- Production Planning & Control
- February 2002 to December 2003, (11 Months)
Education
Diploma - Mechanical Engineering
Thanapandiyan Polytechnic
Madurai, Tamil Nadu01.2001
Secondary School Leaving Certificate - undefined
Magaikarasi Higher Secondary School
Madurai, Tamil Nadu01.1998
Skills
Technical leadership
Engineering principles
Design thinking
Data collection
Effective communication
Training and mentoring
Quality assurance
Project management
Risk assessment
Change management
Quality assurance controls
Cross-functional teamwork
Prototyping
Planning and scheduling
Teamwork and collaboration
Time management
Problem-solving abilities
Team leadership
Certification
Training on MSA, APQP, PPAP, SPC & FMEA.
Disclaimer
I hereby declare that, the above information furnished by me is correct up to my knowledge and I hear the responsibility for the correctness of the above-mentioned particulars.
Key Result Areas
- Team Supervision: Leading, mentoring and motivating teams while ensuring compliance to the laid guidelines. Imparting training to the team members and channel partners for enhancing their skill levels. Spending the meeting with subordinates and other Department Managers, analysing production data, and reviewing production targets.
- Significant Achievements: Reduced major in-house Rejections (Through Why-why Analysis, Kaizen, Poka yoke, QC story). Judged the conformity of the components & Process to the established standard and taken suitable corrective action when deviations are found. Reduced radial /lateral run out in CV wheels through new process techniques. Reduced static unbalance in LCV wheels through process improvements
Accomplishments
- Used Microsoft Excel to develop Testong tracking spreadsheets.
- Achieved co-relation by introducing Strain Gauge measurements for all Projects
- Supervised team of 10 staff members.
- Calculate Carbon footprint & Life Cycle Assessment for LP Wheel.
- ISO 17025 Certification for our ASD Test Center
Additional Information
- Lean tools Implementation in our Test center.
- ISO 17025 Certification for our Test Center
Timeline
Assistant Manager – R&D Test Center
Wheels India Limited
02.2020 - Current
Assistant Manager – Manufacturing & Quality
Wheels India Limited
12.2014 - 01.2020
Senior Engineer - Manufacturing
Wheels India Limited
07.2010 - 11.2014
Engineer - Quality Assurance
Wheels India Limited
05.2004 - 06.2010
Trainee & Apprentice
Delphi-TVS
02.2002 - 12.2003
Secondary School Leaving Certificate - undefined
Magaikarasi Higher Secondary School
Diploma - Mechanical Engineering
Thanapandiyan Polytechnic
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