SARAVANA KUMAR
Hyderabad,Telangana
Summary
Results-driven executive with 26+ years of leadership experience in the Aerospace Industry, specializing in Quality Management Systems, Supplier Quality, Sourcing, and Business Process Optimization. Proven expertise in APQP, Lean methodologies, Root Cause Analysis (5 Why, CAPA), and Total Operational Performance (TOP) initiatives.
Adept at driving continuous improvement, standardizing workflows, and leading cross-functional teams across multiple sites and global suppliers. Strong analytical problem-solver with a track record of enhancing operational efficiency, reducing costs, and fostering high-performance cultures. Skilled in managing diverse teams and aligning strategic objectives with measurable business outcomes.
Overview
29
29
years of professional experience
1
1
Certification
Work History
GENERAL MANAGER & HEAD - CORPORATE QUALITY SYSTEMS & SUPPLIER QUALITY
TATA ADVANCED SYSTEMS LTD
01.2015 - Current
- Strategic Quality Leadership:
Proven track record in establishing and managing enterprise-wide Quality Management Systems (QMS) across multiple manufacturing sites, ensuring compliance with AS9100, ISO 9001, ISO14001, ISO 45001, ISO 50001, EASA Part-21G, and NADCAP standards. - Regulatory & Customer Audit Management :
Successfully led audits for FAA, EASA, Boeing, Airbus, and Lockheed Martin , maintaining zero major non-conformities and ensuring uninterrupted production approvals. - Cost of Quality Reduction : Spearheaded initiatives to reduce Cost of Poor Quality (COPQ) by 30%+ through root cause analysis (RCA), 8D, and Poka-Yoke methodologies.
- Supplier Quality Governance :
Directed global supplier qualification, audits, and performance monitoring (India, USA, Europe), improving defect rates by 25% and ensuring on-time delivery. - Operational & Process Improvement :
Drove Lean/Six Sigma, digital & Technology initiatives, optimizing quality processes and reducing waste, resulting in 35% cost savings annually. - New Product Development (NPD) :
Integrated APQP, PPAP, and FMEA into NPD cycles, ensuring seamless transitions from design to production. - Risk-Based Decision Making :
Implemented risk management frameworks to mitigate supply chain and manufacturing risks. - Team Leadership & Development : Built and mentored high-performing quality teams , fostering a culture of continuous improvement and accountability.
DEPUTY GENERAL MANAGER - QUALITY
TATA LOCKHEED MARTIN AEROSTRUCTURES LTD
12.2011 - 12.2014
- End-to-End Quality Oversight: Direct all QA functions, including supplier quality, sourcing, and compliance, ensuring adherence to AS9100, EAR, ITAR, and regulatory standards.
- Risk-Based Audits & Assurance: Lead audit scheduling and assurance programs aligned with business goals and customer expectations (e.g., Lockheed Martin).
- Cross-Functional Collaboration: Partner with Operations, Engineering, and Supply Chain to meet stringent customer requirements, optimizing inspection processes within takt time for on-time delivery.
- Root Cause & Corrective Action: Established a robust RCA/CAPA process to resolve quality escapes and prevent recurrence, enhancing systemic reliability.
- Process Optimization: Spearheaded CI initiatives, reducing defects and improving first-pass yield (FPY).
- Supplier Quality Management: Conducted supplier audits & performance evaluations, mitigating risks and ensuring aerospace-standard compliance.
- Supplier Development: Strengthened programs to enhance incoming quality and reduce non-conformance costs.
- Performance Metrics & QMS Health: Developed standardized internal quality metrics to monitor and continuously improve QMS effectiveness.
SENIOR MANAGER - QUALITY
TATA ADVANCED SYSTEMS LTD
06.2009 - 11.2011
- Quality & Compliance Leadership: Oversee all aspects of QA operations, including planning, budgeting, staffing, and technical direction to ensure a cost-efficient quality system, regulatory compliance, and a safe work environment aligned with organizational priorities.
- Process Excellence: Lead cross-functional teams in production process analysis, quality standard enforcement, and continuous improvement initiatives to enhance product reliability and efficiency.
- Regulatory & Compliance Management: Ensure adherence to FAA, AS9100D and corporate policies while driving site compliance and supporting customer/internal audits.
- Stakeholder Collaboration: Partner with leadership to define and implement quality process improvements, organizational changes, and industry best practices.
- Customer & Team Development: Cultivate strong relationships with internal/external customers while fostering team growth through mentorship, process optimization, and KPI-driven performance.
MANAGER - QA
TRUSTED AEROSPACE & ENGG PVT LTD
02.2008 - 05.2009
- QMS Compliance & Directed audits (customer, regulatory, internal) and managed Non-Conformance Reports (NCRs) and Escape Notifications with suppliers and customers.
- Led root cause analysis (8D, DIVE) and implemented preventive/corrective actions (CAPA) to mitigate recurring defects and improve process reliability.
- Analyze quality performance metrics to identify trends, reduce escapes, and drive continuous improvement initiatives.
- Collaborated with cross-functional teams (Engineering, Operations, Supply Chain) to resolve non-conformances, supplier defects, and customer complaints through structured problem-solving.
SR. DEPUTY MANAGER - QA
SNECMA HAL AEROSPACE PVT LTD
07.2006 - 01.2008
- Developed and implemented Quality Manuals & Procedures, ensuring compliance with AS9100/EN 9100 standards.
- Led customer & regulatory audits (internal, external, third-party), driving adherence to aerospace quality requirements.
- Reduced defects through NCR management, CAPA, FMEA, and rejection analysis, ensuring robust corrective actions.
- Trained and mentored teams in problem-solving techniques (8D, 5 Whys, Poka-Yoke), fostering a culture of quality excellence.
DEPUTY MANAGER - QUALITY
DYNAMATIC TECHNOLOGIES LTD
08.1996 - 06.2006
- Ensure full compliance with AS9100, customer requirements, and regulatory standards through robust QMS management, audits, and procedure reviews.
- Oversee internal/external audits, root cause analysis (RCA), and timely resolution of customer complaints, non-conformances (NCRs), and corrective actions (CAPA).
- Drive systematic problem-solving (8D, 5 Whys) to enhance processes and reduce defects.
- Monitor and report key metrics (on-time corrective actions, audit closures, FAI approvals).
- Authorize First Article Inspections (FAI) and manage non-conformance documentation, assessing impact on production and quality systems.
Education
M. TECH - AEROSPACE ENGINEERING
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY(JNTU)
Hyderabad01-2013
BACHELOR OF ENGINEERING - MECHANICAL
ANNAMALAI UNIVERSITY
Chidambaram01.1993
DIP. IN BUSINESS ADMINISTRATION -
NATIONAL INSTITUTE OF LABOR MANAGEMENT
Chennai01.2001
Skills
- Quality Systems & Compliance: Designed, implemented, and maintained QMS (ISO 9001, AS9100, ISO 14001, ISO 45001, ISO 50001, EASA Part-21G) across all manufacturing sites using TQM methodologies
- Customer Audits & Regulatory Management: Conducted and managed audits for FAA, EASA, Boeing, Lockheed Martin, and Airbus, ensuring compliance with industry standards
- Cost of Quality (COQ) Reduction: Optimized processes to minimize Non-quality costs while meeting performance targets
- Global Supplier Quality Management: Led Supplier sourcing, audits, and product clearance across India, USA, and Europe, ensuring quality compliance
- New Product Development (NPD): Integrated advanced quality tools & technologies to enhance product reliability and efficiency
- Continuous Improvement (CI): Drove Process optimization, digital transformation, and People development for operational excellence
- Risk & Problem-Solving: Applied 8D, 5 Whys, CAPA, RCA, and Poka-Yoke to mitigate risks and resolve quality issues
- Team Leadership & Development: Built high-performing teams through Strategic hiring, training, mentoring, and KPI-driven performance management
Certification
- LEADERSHIP WINGS - TATA and DEAKIN University, Australia.
- EASA PART 21 G AVIATION LEGISLATION - AERO - Bildungs GmbH. Germany.
- TATA BUSINESS EXCELLENCE - SILVER - TATA Quality Management Services, India.
- AS9100, ISO 18001, ISO 14001 INTERNAL AUDITOR - Nvt Consultancy, India.
- EXPORT-IMPORT MANAGEMENT - Visvesvaraya Industrial Trade Centre, India.
Training
- CYBER SECURITY AWARENESS - TATA Advanced Systems, Hyderabad, India.
- TATA BUSINESS EXCELLENCE MODEL - Tata Advanced Systems, Hyderabad, India.
- TOTAL OPERATIONAL PERFORMANCE - Tata Advanced Systems, Hyderabad, India.
- ACHIEVING COMPETITIVE EXCELLENCE - Hamilton And Sundstrand, PWC.
- SIX SIGMA GREEN BELT - Trusted Aerospace, Chennai, India.
- PREVENTION OF SEXUAL HARASSMENT - Tata Advanced Systems, Hyderabad, India.
Awards
- JEH AWARD FOR EXCELLENCE - Tata Advanced Systems, Hyderabad, India.
- ORDER OF MERIT - Tata Advanced Systems, Hyderabad, India.
- PIONEER AWARD - Tata Advanced Systems, Hyderabad, India.
- APPRECIATION LETTER - DCMA (Defence Contract Management Agency), US Defence, USA.
Timeline
GENERAL MANAGER & HEAD - CORPORATE QUALITY SYSTEMS & SUPPLIER QUALITY
TATA ADVANCED SYSTEMS LTD
01.2015 - Current
DEPUTY GENERAL MANAGER - QUALITY
TATA LOCKHEED MARTIN AEROSTRUCTURES LTD
12.2011 - 12.2014
SENIOR MANAGER - QUALITY
TATA ADVANCED SYSTEMS LTD
06.2009 - 11.2011
MANAGER - QA
TRUSTED AEROSPACE & ENGG PVT LTD
02.2008 - 05.2009
SR. DEPUTY MANAGER - QA
SNECMA HAL AEROSPACE PVT LTD
07.2006 - 01.2008
DEPUTY MANAGER - QUALITY
DYNAMATIC TECHNOLOGIES LTD
08.1996 - 06.2006
M. TECH - AEROSPACE ENGINEERING
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY(JNTU)
BACHELOR OF ENGINEERING - MECHANICAL
ANNAMALAI UNIVERSITY
DIP. IN BUSINESS ADMINISTRATION -
NATIONAL INSTITUTE OF LABOR MANAGEMENT
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