SAURABH KUMAR

Company Overview: BorgWarner is an American 130 years old organization providing solutions in Mobility having 90+ Plants over the globe. At Manesar Plant is manufacturing Products in Exhaust Gas Management and Battery Cooling Systems.

• Leading End-to-End Plant Quality Operations, ensuring robust quality systems from raw material receipt to final product delivery.
• Driving customer satisfaction through consistent delivery of defect-free products and prompt, effective responses to queries and concerns.
• Resolving customer concerns with root cause elimination measures, ensuring zero recurrence for Zero KM defects and field failures.
• Implementing strategies to reduce Cost of Poor Quality (COPQ) through process improvements, waste elimination, and defect prevention.
• Ensuring compliance with Quality Management Systems (QMS) across the entire supply chain.
• Managing supplier quality for 70+ global suppliers, ensuring defect-free supplies from product development to serial production.
• Monitoring and improving process quality through regular shop floor audits, implementation of Poka-Yoke, and team training; maintaining strict adherence to process flows without deviation.
• Driving Advanced Product Quality Planning (APQP) for new product launches, auditing gate checklists, and securing customer PPAP approvals and milestone achievements.
• Optimizing resource utilization across all quality functions for maximum efficiency and impact.
• Leading change management initiatives from supplier approval to customer acceptance for design, process, and material changes.
• Preparing and monitoring quality department budgets, ensuring cost control and resource optimization.
• Leveraging global management information systems via Power BI and other quality dashboards for real-time quality performance tracking.
• Analyzing data and trends to provide actionable insights for informed management decision-making.
• Serving as the key contact for external audits in compliance with QMS requirements (IATF 16949, ISO 9001, etc.).
• Delivering training programs on quality tools, problem-solving methodologies, and effective communication skills to enhance team capabilities.

Company Overview: Sona BLW Precision Forgings Limited is the largest producer of Differential Bevel Gears and one of the pioneer supplier of Differential Assemblies with Final Drive Gear to Electric Vehicle OEMs. Product Line also includes, Spiders, Off-Highway Gears and Helical Gears. Organization is TPM Excellence Award and TPM Consistency Award Certified from JIPM, Japan & practicing TQM.

• Ensuring delivery of quality products by establishing, implementing, and enforcing robust quality systems across all operations.
• Investigating failures, identifying root causes and accountability, and initiating effective corrective and preventive actions.
• Interfacing with customers to understand process and product requirements, facilitate customer audits, and address special requirements.
• Monitoring customer portals for quality concerns and scorecards, driving improvement actions to enhance performance ratings.
• Ensuring defect-free manufacturing at all process stages through application of quality tools and systematic rejection reduction initiatives.
• Leading rejection review meetings with cross-functional teams (CFT) to develop and implement improvement actions.
• Conducting audits including Embedded Tests, Layered Process Audits, and Process & Product Validations to achieve zero-defect objectives.
• Establishing and maintaining effective measurement systems and Poka-Yoke mechanisms in manufacturing and assembly processes.
• Deploying statistical tools (Run Charts, X-bar R Charts, X-MR Charts) to identify process variations, detect special causes, and stabilize manufacturing processes.
• Ensuring first-time-right part development in alignment with customer requirements.
• Defining and implementing quality standards in collaboration with NPD and production teams by studying product requirements.
• PPAP Approvals from Customers along with complete documentation.
• Supplier Quality Management, driving corrective actions, and conducting regular supplier audits to enhance quality levels.
• Evaluating and approving new suppliers for procurement or job-work services, including PPAP validation.
• Change Management implementation and approvals from respective authorities.
• Preparing and managing annual quality budgets, controlling costs while meeting operational requirements.
• Developing and delivering training modules on quality systems, tools, and best practices to enhance team capability.
• Building and managing a high-performance quality team through recruitment, orientation, training, coaching, and performance management.
• Serving as Management Representative and qualified auditor for ISO 9001:2015, IATF 16949:2016, and ISO 14001:2015 (Integrated Management System), managing all MR-related activities for internal and external audits.
• Updating monthly MIS reports and organizing Management Review Meetings to track progress and drive continuous improvement.

• Ensuring on-time customer deliveries by maintaining strict adherence to quality standards and delivery commitments.
• Reviewing and confirming customer schedules, aligning production and logistics plans to meet or exceed expectations.
• Improving Overall Equipment Effectiveness (OEE) by systematically identifying and reducing production losses.
• Maintaining process flow compliance throughout the supply chain and optimizing inventory levels in line with company norms.
• Preparing and managing plant budgets, ensuring optimal allocation and utilization of resources for maximum productivity.
• Implementing lean manufacturing practices such as Standard Work Combination (SWC), line balancing, process layout optimization, and Heijunka planning to enhance operational efficiency.
• Reducing equipment downtime through the implementation of a comprehensive preventive maintenance program.
• Increasing productivity by optimizing labor allocation, improving scheduling, and balancing workloads across multiple shifts.
• Managing staff training programs to upskill employees in the latest industry practices and safety requirements, covering areas such as Daily Work Management (DWM), Layered Process Audits (LPA), SMED, SPC, and trend analysis.
• Enhancing plant safety standards by conducting detailed risk assessments and implementing proactive safety protocols.
• Driving workplace organization and visual management improvements through rigorous adherence to 5S and TPM practices.
• Serving as the primary contact for external audits, ensuring full compliance with customer, industry, and regulatory requirements.

Company Overview: Hitachi Metglas India Pvt Ltd. is 100% EOU subsidiary engaged in manufacturing of amorphous metal electronic cores, used in various electrical & electronic devices. Organization is certified with ISO/TS 16949, ISO 9001, ISO 14001 and OHSAS-18001.

• Driving new product development, including the designing of tooling, jigs, fixtures, & inspection gauges.
• Preparing accurate raw material and consumables BOM for new product costing and feasibility analysis.
• Managing commercialization of samples to production through complete Technical Package (Internal PPAP) approvals. Successfully commercialized 8 New Parts.
• Establishing new equipment and processes in the shop floor and implementing improvements in existing processes for enhanced capacity & efficiency.
• Owning and maintaining all process documentation, including Work Instructions (WIs), Specifications, Standard Operating Procedures, Process Flow Charts (PFCs), Control Plans, PFMEAs, and related records.
• Implementing exhaust ducting systems for ovens, cutting machines, and other equipment at the new manufacturing site.
• Updating and validating BOM and routing (cycle times) in eBAAN ERP for all products to ensure accurate production planning.

Company Overview: DELPHI – Electric Packard System Organization is 100% subsidiary of Delphi Corporation, USA. Delphi is engaged in producing Wiring Harnesses for Passenger Cars, HCV, LCV, Tractors and Off Highway Vehicles. First Wiring Harness Manufacturer to obtain ISO/TS 16949 in India.

• Ensuring achievement of customer milestones during new program development, meeting all timeline and quality requirements.
• Developing comprehensive project plans with active team participation and leading formal project kick-off meetings.
• Conducting APQP team meetings to track project risks, implement corrective measures, and ensure alignment with program goals.
• Managing the complete Product Development Process (PDP), organizing PDP management reviews, and ensuring availability of resources and materials for smooth product release into regular production.
• Providing regular updates to management on program status, including identification and mitigation of financial risks.
• Monitoring planned vs. actual project expenditure and implementing cost control measures where necessary.

SECTION ENGINEER - PROCESS ENGINEERING Aug 2003 ~ Nov 2006

• Conducting feasibility studies of customer drawings and implementing design modifications in line with forging norms; responding to customer inquiries for forged differential gears and pinions.
• Designing tools, dies, jigs, and gauges required for manufacturing new products, ensuring adherence to quality and process requirements.
• Managing APQP for each new development, ensuring achievement of customer milestones through timely submission of initial samples as per specifications.
• Preparing detailed process documentation, including Process Instruction Sheets, Control Sheets, and Inspection Sheets for every manufacturing stage.

ENGINEER - PRODUCTION Feb 2000 ~ Aug 2003

• Leading production operations equipped with forging press lines, cutting machines, hydraulic presses, CNC machines, angular grinders, broaching machines, honing machines, and SPMs for differential case housing machining.
• Achieving production targets and monitoring Overall Equipment Effectiveness (OEE), analyzing data to improve shop performance.
• Driving productivity improvement and rejection reduction initiatives through process optimization and defect prevention measures.
• Planning and procuring dies, cutting tips, and production tools, while monitoring and optimizing tool life.
• Conducting regular operator training on machine operations, safety practices, 5S, waste reduction, TPM principles, and QC tools for problem solving.
• Implementing Kaizens and Poka-Yoke solutions to eliminate rejections, enhance productivity, and improve process stability.