SANU SAINI

Company Profile : APL Auto Components Pvt. Ltd., located in IMT Bawal (Haryana), is a highly export-focused engineering and manufacturing company specializing in precision-machined automotive and non-automotive components. With 95% of its production exported worldwide, APL is recognized as a trusted global supplier of high-precision and safety-critical components.

The company manufactures a wide range of products using forgings, castings, tubular components, and bar stock, catering to high-performance applications in two-wheelers, four-wheelers, dampers, vibration-control systems, and engine powertrain assemblies, FMCG assy components

Job responsibilities :

• Monitor and control key departmental KPIs including Internal PPM, External PPM, COPQ, FTQ, Rejection %, and Customer Complaints.
• Develop departmental KPI targets aligned with organizational goals and ensure effective execution across all quality functions.
• Lead daily, weekly, and monthly quality performance reviews to track KPI progress and initiate corrective actions where gaps are identified.
• Drive reduction in Internal PPM and scrap rate through process control, root cause elimination, and continuous improvement initiatives.
• Control Customer PPM and ensure 0 major customer complaints by leading structured problem-solving using 8D, 5 Why, and CAPA.
• Ensure 100% on-time closure of corrective and preventive actions (CAPA) for internal, customer, and supplier-related issues.
• Monitor Supplier PPM and Incoming Quality levels and continuously improve through supplier development and audits.
• Achieve First Time Quality (FTQ) targets by strengthening in-process inspection, error-proofing, and operator training.
• Ensure 100% compliance to Quality Management System (IATF 16949/ISO 9001) and meet all internal/external audit KPI requirements.
• Improve Inspection Efficiency KPI by optimizing manpower utilization, strengthening inspection standards, and upgrading metrology.
• Control calibration KPIs by ensuring 100% timely calibration of gauges, fixtures, and measuring instruments.
• Achieve APQP/PPAP on-time submission KPI by coordinating with NPD, production, and suppliers for documentation readiness.
• Reduce Cost of Poor Quality (COPQ) through scrap reduction, rework control, process stabilisation, and mistake-proofing.
• Maintain 100% compliance for process audits, product audits, and LPAs and track closure of non-conformities for audit score improvement.
• Develop skill matrix and training effectiveness KPIs for quality inspectors, engineers, and auditors to improve departmental capability.
• Mentored junior team members, fostering a culture of continuous learning and professional development within the department.
• Adapted quickly to changing priorities and market demands, ensuring timely delivery of high-quality products under tight deadlines.
• Developed and maintained detailed documentation of all QA procedures, ensuring consistent application across the organization.
• Led training sessions for new hires and ongoing professional development workshops for existing staff members, sharing expertise in quality assurance methodologies and techniques.
• Optimized resource allocation by accurately forecasting project requirements and effectively managing available personnel and equipment resources.

• Managed end-to-end Quality Management System (IATF 16949 / ISO 9001) including audits, documentation, and compliance.
• Led customer quality, handled complaints, and executed 8D, 5 Why, and root-cause analysis to prevent recurrence.
• Ensured in-process and final inspection quality across machining/assembly lines and reduced internal PPM.
• Coordinated APQP, PPAP, control plan, and PFMEA activities for new product development.
• Monitored supplier quality performance, conducted supplier audits, and drove corrective actions.
• Implemented continuous improvement projects (Kaizen, Lean) to reduce defects, rework, and quality costs.Responsible for In process and supplier quality control as per process and product characteristic standard to control defects and line rejection
• Make action plan 8D, Why- Why, 4M Analysis, Problem Counter Measure Report after analysis for quality problems and take corrective and preventive action against root causes of quality trouble case.

• Construction and revision of SOP Standard operating Procedures for the inspection function & Assist in the writing and updating of Inspection Procedure and check lists.
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• Maintain parts rework trend PPM and analysis by Q.C. Tools and take Corrective and preventive action against defects.
• Customer complaint handling for analyzing actual problem root cause and interaction with customer by effective communication.

• Focusing on Customer satisfaction by reducing 0 % rework and 100% supplier quality rating.
• Rejection analysis all shifts with Team leaders and Engineers by daily rejection meeting.
• Responsible for supplier or job workers visit as per plan and prepare improvements plan required actions against last month high ppm parts.

Leading and monitoring a team of 40 person’s at one time.

• Training & educating associates for creating Awareness for Quality activities.
• Analyzing internal rejection percentage for PPM controlling and executing internal audit for key point’s improvements.
• Responsible for new sample approval and quality assurance visit for mass production at supplier end.
• New product trial& set up of new molds with development team.
• Develop and change the quality control procedures and policies of organization
• Eliminate waste and inefficiencies in manufacturing facilities by recommending process improvements
• Drive quality improvements by identifying issues, developing solutions and effectively communications
• Study requirement ,cost and team members to develop an effective project management plan
• Leveraging strong analytic skills, study product specifications, shipping costs effective and other factors, and use models to design processes that will help achieve quality goals.
• Take new responsibility as a challenge and complete works under the target dates to prove yourself for management and organization.
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• Responsible for Molding line In process quality control as per process and product characteristic standard to control defects and line rejection
• Make action plan after analysis for quality problems and take corrective and preventive action against root causes of quality trouble case.
• Patrolling inspection of parts during process and cross verification according to define quality standard requirements.
• Construction and revision of SOP for the inspection function & Assist in the writing and updating of Inspection Procedure and check lists.
• To prepare monthly COPQ rating, PPM, rejection report and monthly Top rejection parts analysis with action plan by brain storming with concerns persons and department.
• Maintain parts rework trend and analysis by Q.C. Tools and take Corrective and preventive action against defects.
• Customer complaint handling for analyzing actual problem root cause and interaction with customer by effective communication.
• Responsible of customer and internal audits like product and process as per plan.
• Responsible for incoming parts inspection and supplier or job work audit for improvement.
• Focusing on Customer satisfaction by reducing 0 % rework and 100% supplier quality rating.
• Rejection analysis both shifts with Team leaders and Engineers by daily rejection meeting.
• Responsible for supplier or job workers visit as per plan and prepare improvements plan required actions against last month high ppm parts.
• QMS Documentation as per TS 16949-2009 & IATF 16949-2016 or other specific customer requirements.
• Leading and monitoring a team of 10 person’s at one time.
• Training & educating associates for creating Awareness for Quality activities.
• Roop polymers ltd. (RPL) is the flagship company of the Roop group. With over 35 year of rich experience in the automotive industry, Rpl today is a world class manufacturer of molded and extruded rubber & plastic parts for automotive OEM around the globe. (Polyvinyl chloride), TPE (Thermoplastic rubber) etc. all plants are TS-16949-& ISO 14001 certified and meet the most stringent quality norms set by its diverse range of customers. It offers a one stop shop engineering solutions to all the customers through its expertise in designing, development, tooling, molding, extrusion, assembly, painting, testing and delivery capabilities across the globe. RPL is a part of supplying to automotive majors in India like Maruti Suzuki, Honda, Hero motocorp, Bajaj auto, Escorts, Indian railway, Honda power products etc. RPL is also a major supplier to TRW USA for their critical rubber parts impairment. RPL today has become a supplier of choice for the Indian automotive industries.

• Customer complaint handling and analyzing for problems at customer end.
• Take corrective actions and preventive actions for prevention control of defects to passing customers.
• Responsible for implementing the countermeasure on shop floor which is decided by CFT or management to control problems at customer.
• Responsible for Process & Product Audit & Implementation of Action plan
• Responsible for analysis of major lines problems and Reduce of Losses Level by using Q.C. tools and making action plans
• Responsible for taking deviation related to quality issues (not effect to customer requirements)
• Approving the master sample and its reports and take approval of limit sample from quality head.
• Co-ordinate with tool room for the modification & correction tools and fixtures.
• Inspection of molded & assembled part such as bush, top mount, hinged pendulum support
• To ensure identification, tracibility & routine inspection of parts as per inspection standard
• Responsible for making the fixture validation as per plan
• Responsible for operate the customer portal and maintaining the daily performance sheet on daily basis
• Kaizen & poke –yoke implementation on shop floor
• Rejection analysis with Team leaders and Engineers by daily rejection meeting .
• Analyzing problems of production lines and take corrective and preventive action against problems.
• The Jayashree Group traces its roots back to 1984 when it began operations as a metal & Rubber manufacturing company. Jayashree, realizing the immense opportunities in the global rubber components industry has been successful in expanding its operations into multiple locations & multi-products over a period of time. JPPL boasts of a steady growth since its inception. While acquiring latest technology for development and production, we have steadily been introducing innovative products and providing customized solutions for various business sectors .we have continuously upgrade our technology to keep pace with the stringent industry requirement .It has established itself as one of the leading automotive metal, rubber components supplier in the country for our most perspectives customers like Hmcl, Tml, Continental, Jcb, Honda, Tvs, Maruti, Renault, Nissan, ford etc.