Vijayakumar S
Process Quality Senior Engineer
Arni
Summary
Dedicated and knowledgeable manufacturing professional with diverse industry knowledge and special talent for searching out opportunities for improvement, contributing to cost reduction, increased productivity and waste reduction. Provides objective analysis and innovative solutions to a wide range of manufacturing problems, cost and productivity optimization, and safety and environmental issues. Knowledgeable in MiG Welding, Spot welding, & Robo welding V-cell & H-wander and In Process Quality, Demonstration of cross-functional knowledge with proved operational success.
Overview
14
14
years of professional experience
1
1
Language
Work History
Quality Engineer (In process Quality)
Faurecia Emission Control Technology’s India Pvt Ltd
- Overall Experience 14 Years,(Production 09 Years & Quality 5 Years)
- Current Role: Senior Engineer – In process Quality, December 2020 – Still Now.
- Previous Role: Quality Representative Engineer KIA Motors, June 2020 – November 2020.
- Previous Role: Production Supervisor Engineer, April 2019 – May 2020.
- Previous Role: Team Leader, May 2015 – March 2019.
- Previous Role: New Project Leader September 2014 – February 2015.
- Previous Role: Operating Engineer, Dec 2011 – August 2014.
Engineer – Process Quality
Faurecia Emissions Control Technologies India Pvt. Ltd.
12.2020 - 01.2025
- In-process Quality aspects in everyday production, checking fixture conformance, Inspection Reports & SDS
- Organize and participate to all technical meetings with the customer (Solve technical problems, manage changes, progress path, …) and ensure all validations as required by customer are completed.
- Handling Process Audit, Product Audit and Customer Audits such as Toyota CPPP and IATF 16949
- Ensuring quality conformance in new exhaust projects related to Toyota, Kia and Maruti Suzuki
- Ensuring quality conformance in internalization projects
- Drives Customer Complaint Resolving Process, Ensuring Robustness of Problem Solving (8D)
- Warranty Part Analysis and Customer Support for Same
- Participate actively to the Engineering Change Request deployment.
- Reduction of Customer Complaints and line Rejection
- CMM Inspection of parts and checking fixtures
- Quality Conformance audits
- Daily monitoring of Line Performance on Quality aspects
- Drive and ensure all customer specific requirements within defined perimeter.
Production Supervisor Engineer
Faurecia Emission Control Technology’s India Pvt Ltd
01.2011 - 01.2019
- Roles and Responsibilities:
- Assembly process planning, facility planning and layout design for new products
- Ability to sequence the assembly process by analyzing the drawing
- Define cycle time online within the Takt time and standard operations
- Define production equipment specifications & Follow-up production equipment build
- Release manufacturing process documents, Standard instructions, Process Parameters
- Carry out process productivity analysis & Manage production equipment performance (DLE, TRS)
- Trouble shooting & Support to solving the process problem
- Contributing to the Engineering Change Management process
- Reduction of Internal scrap & rework in terms of improving quality.
- Conduct the SMED & cycle time reduction
- Conduct the Pre-Production trial, Run at Rate
- Drive the Team to Achieve Green launch and BSVI CUMMINS (Ashok Leyland and Tata Vehicle 2020).
- For Hot end assembly, Monolith Reverse Loading Identification Template & check point added Regulatory Issue.
- Lead the Team VP Build for BS6 and complete in very short deadline, got appreciation from Organization.
- Lead FCA BS6 Project and completed PT and MPT Achieving 85 % capacity respectively.
Education
Diploma - Mechanical Engineering
Sree Venkateshwara Polytechnic College
06.2011
SSLC - Class 10
Government Higher Secondary School
03.2008
Skills
SW Creation
QRCI Like 8D, Why-Why Analysis, Fish Bone Analysis
Poke Yoke creation
In Process Quality Document (Control Plan, Process Flow, PFMEA, ok 1s part, Welding Boundary Samples, Final Inspection WI, Final Inspector validation, etc)
Handling Process Audit, Product Audit and Customer Audits
Ensuring quality conformance in new exhaust projects related to Toyota and Kia (Kia Sonnet) and Maruti Suzuki (Grand Vitara)
Ensuring quality conformance in internalization projects of 560B IPRT and MSIL IPRT Innova Hy cross
MiG welding
Tig Welding
Robo V- cell Programing
MIG welding troubleshooting and assemble the two components
TIG welding using for doing re-work and process
ROBOTIC welding troubleshooting
Method of welding and create work instruction
SAP
Manufacturing routing and production version updating
BOM checking and error, part number, Part name maintain
Production, Scrap
MS Excel
MS Office
Accomplishments
- Reduction of scrap 1.0 % to 0.8 %
- Manpower reduction in all assembly lines 08 manpower major contribution.
- Cycle time reduction in Weakening by milling machine due to bottle neck machine 115sec to 96sec.
- Change over time reduction in V- cell by conducting SMED 30min to 15min.
- Cycle time reduction in Pre-Leak Testing for improving OEE 66sec to 60sec.
- In Kaizen Competition won First Price on 2014 Regarding, Provide Poka Yoke’s which is critical to Customer in FMEA Reduce the RPN Value (Hole Presence Mechanical Pin).
- Drive the Project to Achieve Green Launch on Innova Crysta Vehicle 2015.
- Reduce the Change Over Time by Given Kaizen Regarding, Two more Variants, Suggested Top Side One Model and Another Variant Downside on Fixture Bed (5 second Fixture Change Over Complete).
- Reduce the Change Over Time by Given Kaizen Regarding, Each Station Wise Maintain SIP to Take First Piece Earlier (1 hour to 30 Minutes).
DECLARATION
I hereby declare that all the details furnished above are true to the best of my knowledge and belief. Place : Bangalore Date
Key Career
- Internal Auditor for FES
- Cost savings for Tube length reduction -1,25,000/-
Timeline
Engineer – Process Quality
Faurecia Emissions Control Technologies India Pvt. Ltd.
12.2020 - 01.2025
Production Supervisor Engineer
Faurecia Emission Control Technology’s India Pvt Ltd
01.2011 - 01.2019
Quality Engineer (In process Quality)
Faurecia Emission Control Technology’s India Pvt Ltd
SSLC - Class 10
Government Higher Secondary School
Diploma - Mechanical Engineering
Sree Venkateshwara Polytechnic College