SUDHAKAR G. MAHADIK
Process Quality Head
Mumbai
Summary
Senior Process Quality Lead with 12+ years of experience in automotive, EV, and battery manufacturing, driving process stability, defect prevention, and manufacturing excellence. Proven track record in customer PPM reduction, FTR improvement, SOP readiness, and NPQ support. Strong expertise in PFMEA, APQP, PPAP, control plans, and IATF 16949 compliance. Experienced in leading large manufacturing teams, managing OEM interfaces, and improving supplier and incoming quality. International exposure through China cell manufacturing plant audits, enabling deep understanding of cell processes and risk mitigation. Recognized for data-driven problem solving and hands-on leadership.
Overview
11
11
years of professional experience
3
3
Languages
Work History
Process Quality Head / Dy. Manager – Process Quality
TATA AUTOCOMP GOTION GREEN ENERGY SOLUTIONS PVT. LTD.
Pune, India
01.2025 - Current
- Lead the Process Quality function across EV battery manufacturing with 14 direct and 180+ indirect personnel.
- Own the process quality strategy, governance, KPIs, and compliance for manufacturing operations.
- Ensure robust process controls, layered process audits, and defect prevention for safety-critical products.
- Drive compliance with IATF 16949 and OEM customer quality requirements.
- Act as a single point of contact for OEM customers on process quality performance and escalations.
- Lead cross-functional teams to stabilize processes and improve manufacturing capability.
- Process Quality Lead Responsibilities (Current Role)
- Identified areas for improvement within the department, implementing strategic initiatives to address gaps in performance or resources.
- Improved team efficiency by streamlining processes and implementing innovative management strategies.
Assistant Manager – NPQ & Process Quality
TATA AUTOCOMP GOTION GREEN ENERGY SOLUTIONS PVT. LTD.
Mumbai, India
12.2022 - 12.2024
- Owned New Product Quality (NPQ) from pilot builds to SOP readiness.
- Led PFMEA development, APQP activities, control plan deployment, and risk mitigation.
- Reduced customer PPM from 8000 to 500 within 6 months through RCA and preventive actions.
- Managed customer complaints using 8D, RCA, and CAPA, reducing closure cycle time by 50%.
- Implemented traceability and defect containment systems, improving issue response by 30%.
- Trained engineers, supervisors, and operators on SOPs and quality tools.
- NPQ & Process Quality Responsibilities (2022–2024)
Senior Officer – Quality Assurance
EXIDE INDUSTRIES LTD., TALOJA, MUMBAI
05.2015 - 12.2023
- Leading a team of four engineers in NPD Quality to ensure seamless new product development and process stabilization.
- New Product Quality Planning: Implement APQP, DFMEA, and PFMEA to ensure defect-free Ultra and Gel battery development.
- Process & Manufacturing Quality Assurance: Establish SOPs, SPC, and MSA to maintain high-quality production standards.
- Supplier Quality Management: Qualify and audit suppliers, ensuring IQC and SQA processes for raw materials and components.
- Failure Analysis & Defect Prevention: Conduct root cause analysis (8D, 5Why, Fishbone) and implement CAPA to eliminate defects.
- Warranty & Customer Quality Management: Analyze warranty data, resolve customer complaints, and implement preventive actions.
- Battery Charging & Formation Process: Develop optimized charging programs for improved battery life & performance.
- Field Trials & Reliability Testing: Conduct real-world performance assessments and lifecycle analysis for new batteries.
- Roles & Responsibilities
Education
Bachelor of Engineering - Production
Shivajirao S. Jondhale College of Engineering
Mumbai01.2013
12th Science - Science Education
Bhavan’s College of Science
Mumbai01.2008
10th Common -
Byculla School
Mumbai, India01.2006
Skills
Process Quality Process Quality Lead Manufacturing Quality EV Quality Battery Manufacturing Quality NPQ (New Product Quality) NPD Support APQP PPAP PFMEA DFMEA Control Plan SOP Readiness Customer PPM Reduction 8D Problem Solving RCA CAPA IATF 16949 OEM Quality Systems
Process and procedure development
Conflict resolution expertise Decision-making capacity Problem-solving Decision-making Cost analysis and savings Performance improvementsTask delegation
Accomplishments
- Supported five successful SOP launches with zero customer line stoppages.
- Improved First Time Right (FTR) from 85% to 96%.
- Selected by senior management for a 20-day on-site audit in China for lithium-ion cell manufacturing plants.
- Gained strong understanding of cell manufacturing processes including electrode coating, calendaring, assembly, formation, and aging.
- Streamlined incoming cell quality issues by strengthening audit feedback and inspection standards.
- Built and scaled a strong process quality team to support rapid EV business growth.
Timeline
Process Quality Head / Dy. Manager – Process Quality
TATA AUTOCOMP GOTION GREEN ENERGY SOLUTIONS PVT. LTD.
01.2025 - Current
Assistant Manager – NPQ & Process Quality
TATA AUTOCOMP GOTION GREEN ENERGY SOLUTIONS PVT. LTD.
12.2022 - 12.2024
Senior Officer – Quality Assurance
EXIDE INDUSTRIES LTD., TALOJA, MUMBAI
05.2015 - 12.2023
Bachelor of Engineering - Production
Shivajirao S. Jondhale College of Engineering
12th Science - Science Education
Bhavan’s College of Science
10th Common -
Byculla School
DECLARATION
I hereby declare that the information furnished above is true to the best of my knowledge. Place: Pune SUDHAKAR MAHADIK
PROFILE
- Father’s Name: Ganpat Mahadik
- Mother’s Name: Ashvini Mahadik
- Date of Birth: 21 Aug 1991
- Marital Status: Married
- Nationality: Indian
ORGANISATIONAL EXPERIENCE
- May 2014 – 2015: L&T Switchgear Tool Room, Mumbai – Graduate Engineer Trainee (Quality Assurance).
- May 2015 – 2016: EXIDE Industries Ltd., Taloja – Graduate Engineer Trainee (Quality Assurance).
- 2016 – 2017: Officer – Quality Assurance and New Product Development.
- 2019 – 2022: Sr. Officer Quality Assurance CFT – Customer Service Representative (Core team member of New Lithium-ion Battery Development project at Prantij, Gujarat).
- Dec 2022 – 2024| Assistant Manager – NPQ & Process Quality TATA Autocomp Gotion Green Energy Solutions Pvt. Ltd.
- Jan 2025 – Present Process Quality Head / Dy. Manager – Process Quality TATA Autocomp Gotion Green Energy Solutions Pvt. Ltd.