Santhosh Aradhya
Bangalore
Summary
Strategic Quality and Process Consultant with 20+ years of experience driving business excellence, quality transformation, and stakeholder success in large-scale garment manufacturing and export operations. Proven ability to lead cross-functional programs, build KPI governance models, manage quality systems, support audits, and align operational rigor with enterprise-wide strategic goals. Adept in Lean methodologies, root cause analysis, and data-driven decision-making to enable proc...
Overview
22
22
years of professional experience
1
1
Certification
Work History
Assistant General Manager – Quality
Shahi Exports Pvt. Ltd.
09.2024 - Current
- Spearhead Quality Assurance and Factory Audits (QAFA) ensuring global compliance.
- Defined and monitored KPI metrics and implemented trend analysis and root cause strategies.
- Led process audits, risk reviews, and SOP training rollouts.
- Worked with brands like Nike, Walmart, and CK.
- Achievements: DHU reduced from 8% to 3%, External GMP/QAFA scores >90%, Rejection % from 4% to 1.5%
- Dynamic quality professional with a proven track record of drivingquality assurance, factory audits, and process improvements in thegarment industry.
- Demonstrates expertise in GMP compliance, process audits, andsustainability initiatives to uplift . Adept at leading large teams andcollaborating with international brands to achieve exceptionalproduct quality.
- Key Responsibilities:Spearheading Quality Assurance and Factory Audits (QAFA) toensure adherence to global compliance standards.
- Conducting Good Manufacturing Practices (GMP) and process auditsto maintain high operational efficiency and product quality.
- Driving initiatives to reduce Defects per Hundred Units (DHU),achieving measurable improvements in production quality.
- Managing and mentoring a robust quality team of 120+ members,fostering a culture of continuous improvement and accountability.
- Collaborating closely with international brands, including Nike,Walmart, and Calvin Klein (CK), to meet stringent qualitybenchmarks.Notable Achievements:Achieved External GMP &QAFA Audit Score to >90% .
QA Head / Sr. Quality Engineer
VF Asia Ltd.
10.2010 - 12.2023
- Defined business KPIs, improved audit readiness, and vendor quality upgrades.
- Achieved 98% product testing pass rate, 95% operational efficiency, and significant defect reduction.
- Spearheaded continuous improvement initiatives, reducing SQL by1.75%
- Implemented automated internal testing processes, enhancing product reliability and durability to reduce product failure by 98%every season
- Collaborated with cross-functional teams to refine and improve product features to meet OTP >98%
- Conducted comprehensive quality assessments and provided actionable recommendations to uplift 85% of Vendors to GoldRating 92% of success rate in Certification through Training & Development sessions for Factory Quality Team on Final Inspection Procedures &Process Audits98% pass rate in Product Testing stages in FPT & GPT through LRM before bulk stage
- Established robust operation methods in 68% of repeated styles toimprovise consistency in Product Execution
- Developed Operation dockets as guidelines for batch setting for-most critical operations for 35% of NPI & Complicate styles to achieve Operational excellence.
- Amplified productivity by monitoring team activities and identifying areas for improvement through SWOT Methodology & 15% ofFactories which are in weak were improvised to meet Compliance requirements of VF.
- Achieved 95% significant operational efficiencies and cost savingsthrough process optimisation by simplifying complex operations in RAM & LRM discussion before bulk production.
Quality Assurance Manager
Cosmos Knit SARL
07.2009 - 09.2010
- Led LRM and RAM process discussions.
- Enhanced execution consistency and compliance performance.
- Led a team of 52 workforce, achieving 98% KPI adherence and 70%efficiency in productionSuccessfully reduced end-line defects 5% through targeted quality improvement strategies.
- Developed and implemented in-house quality testing systems,ensuring adherence to brand standards such as home laundry for customer wash for Product durability check.
- Managed relationships with high-profile clients such as Reebok andAdidas with robust communication ensuring on-time delivery and high product Quality of meeting AQL 1.5.
- Proud part of being producing 100% non-wash program REEBOKKnits with capacity of 220K/Month @ 70% efficiency across all thedepartmentAbout twelve expatriates report to me from different sections ofQuality department, in-house Print & Embroidery unit, finishing and shipping Under my leadership our unit successfully .
- implemented the in-house developed Quality Testing's & various system to control cut to-pack details in finger points.
- lead the Success Route map 2009 implementation project in production and Quality department to increase the efficiency from60 to 70% and end line quality DHU from 10 to 6%.
- Have built a good, motivated team to achieve 98% on timeshipment, 70% efficiency in cutting, sewing & finishing, MMR 1:90,End line DHU-6%,>98% fill rate, less than 2% external final audit fail.
- Tracking global market triggers to anticipate stock movements.
Focusing on RailTel and other PSU stocks for potential opportunities.
Watching for correction thresholds to time entry or exit.
Aiming to make informed, strategic investment decisions.
Assistant Quality Manager
Shahi Exports Private Ltd.
05.2007 - 06.2009
- Implemented in-house quality testing systems along with SOP and SPC frameworks to standardize operations.
- Achieved 98% First Pass Rate (FPR) and reduced production defects by 15% through rigorous quality control and root cause analysis.
- Maintained 98% on-time shipments, 70% production efficiency, and an end-line DHU (Defects per Hundred Units) of 6%.
- Trained and managed a 65-member QA team, promoting a culture of quality excellence and continuous improvement.
- Oversaw all technical aspects during product development (P.D/SMS) and implemented pattern adjustments to avoid downstream quality issues.
- Managed full production cycle — from fabric inspection to final dispatch — ensuring top-tier quality and delivery standards.
- Led batch setting and problem-solving initiatives in critical operations to maintain consistent quality outcomes.
- Spearheaded the 'Success Route Map 2009' project, significantly improving key performance indicators across factory operations.
Quality Assurance Officer
ITC Group Limited
07.2003 - 05.2007
- Managed end-to-end quality assurance from raw material inspection to final shipment for domestic brands.
- Implemented Just-In-Time (JIT) system to improve production efficiency and reduce lead times.
- Conducted product development (PD) with fabric behavior analysis and early-stage pattern adjustments.
- Led sample approval processes and aligned bulk production with buyer requirements.
- Monitored inline QC and addressed technical issues during PD and bulk to maintain product standards.
- Coordinated with outsourcing vendors to ensure timely delivery and consistent product quality.
- Prevented customer returns by identifying and resolving quality issues early in the production cycle.
- Focused on zero-return strategy, implementing proactive quality controls to ensure customer satisfaction and on-time delivery.
Education
MBA - Supply Chain Management
Fashion Designing Institute
01.2012
Diploma - Fashion Design
Apparel Training & Design Centre (ATDC)
Bengaluru01.2002
Skills
- Process & Quality Management (QMS, GMP, SOPs)
- Business Transformation & Strategic Execution
- KPI Design & Trend Analysis
- Governance, Risk & Compliance
- Stakeholder & Program Management
- Internal/External Audit Readiness
- Lean Six Sigma & Root Cause Problem Solving
- Training, Mentoring, and Change Leadership
Certification
- Lean Six Sigma
- SOP & SPC Systems
- PDCA
- RCA
- 5 Whys
- JIT & Quality Engineering Tools
Languages
English
Bilingual or Proficient (C2)
Kannada
Bilingual or Proficient (C2)
Tamil
Advanced (C1)
Hindi
Bilingual or Proficient (C2)
Tools Reporting
- MS Excel Advanced
- Power BI
- Google Sheets / Docs
- Quality Dashboards
- Internal Audit Systems
Projects Impact
- Reduced commuting carbon footprint by 40%, eliminated 65% single-use plastic.
- Uplifted 15% of weak factories via SWOT & RCA.
- Led factory-level leadership engagement for measurable process improvement.
Timeline
Assistant General Manager – Quality
Shahi Exports Pvt. Ltd.
09.2024 - Current
QA Head / Sr. Quality Engineer
VF Asia Ltd.
10.2010 - 12.2023
Quality Assurance Manager
Cosmos Knit SARL
07.2009 - 09.2010
Assistant Quality Manager
Shahi Exports Private Ltd.
05.2007 - 06.2009
Quality Assurance Officer
ITC Group Limited
07.2003 - 05.2007
MBA - Supply Chain Management
Fashion Designing Institute
Diploma - Fashion Design
Apparel Training & Design Centre (ATDC)
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