Vishal Nalegaonkar

Results-driven Quality Professional with 9.8+ years' experience driving excellence in Quality Assurance, Quality Management Systems, Supplier Quality Improvement, Accomplished DOJO Trainer and System Trainer with expertise in QMS/ TQM/EMS, New Part Development and education & training within Leading automotive & Non-automotive industries., optimizing products/processes, managing supplier/incoming/in-process/customer quality. Proven track record in QMS, Process Quality and customer Quality, supplier development, team skill-building, ECN/PCN management, and NPD activities from RFQ to production handover. Effective implementation and maintenance of ISO 9001:2015 and IATF 16949:2016 Quality Management Systems, ensuring seamless new product introductions, and facilitating kick-off meetings to align process owners and cross-functional teams (CFT) with customer milestones, deadlines, and CSR objectives. "Currently serving as Supplier Quality at John Deere [Cyient Ltd]"

Won First Prize in the ACMA Quality Circle competition for Productivity Improvement.

Successfully Participated in and Supported 8+ IATF 16949 audits & 40+ Customer audit.

Improved Supplier on -Time PPAP approval rate from 88% to 98%.

Reduced supplier PPM from 1200 PPM to 200 PPM through supplier development and corrective actions.

Reduces COPQ from 2% to 0.5%.

• QMS System Expertise –
• I have expertise in implementing and managing Quality Management Systems (QMS), ISO9001:2015 & IATF 16949:2016
• Knowledge of TQM Deployment and Execution across manufacturing functions and processes.
• Experience in coordinating with cross-functional teams for timely execution of improvement activities.
• Skilled in QC Story, PDCA, 7 QC Tools, Kaizen, TQC, TPM, and Lean Manufacturing practices.
• Ability to prepare and maintain TQM standards, manuals, guidelines, and documentation.
• Experience in continuous improvement activities related to Quality, Cost, Delivery, Safety, and Customer Satisfaction.
• Strong problem-solving knowledge using 8D, RCA, 8D, Why-Why Analysis, and Fishbone Diagram.
• Capable of supporting chronic issue resolution using data-driven approaches.
• Experience in Daily Work Management (DWM), KPI monitoring, visual controls, and review mechanisms.
• Ability to support internal and external quality assessments and audit preparations.
• Skilled in conducting training and supporting employee engagement activities related to quality culture.
• Strong teamwork, ownership, and cross-functional coordination abilities.
• Supplier Quality Management:
• Senior Quality Engineer with 9.8+ years of experience in Automotive Manufacturing, Supplier Quality Assurance, APQP, PPAP, PFMEA, MSA, SPC, IATF 16949, and New Product Development.
• Experienced in managing supplier quality performance, production readiness reviews, process audits, capacity verification, and launch quality activities.
• Strong expertise in APQP, PPAP, PSW approval, 8D problem-solving, supplier development, and cross-functional stakeholder management.
• Proven ability to drive quality improvements, reduce PPM, improve RFT, and ensure successful program launches within timeline and quality targets.
• Provide strong technical guidance & experience on Hot stamping, cold stamping, BIW parts, door panels, tunnel, Cross members, tailgate, roof panel, A & C pillar, Injection moulding, bumper, door trim, machining, coolant pipe, engine parts, extrusion, die casting, brake & clutch cables, plating, painting, crimping, furnace brazing, hydraulic hoses & tubes, fabrication, Tig, Mig & Projection welding, Sheet metal etc.
• Review and approve supplier quality documentation (ITP, QAP, WPS/PQR).
• Implement structured problem-solving methodologies (8D, RCA).
• Key Responsibilities
• Led APQP activities with suppliers to ensure successful product development, production readiness, and timely PPAP/PSW approval for new and existing vehicle programs.
• Participate in IMS audits (ISO9001, ISO45001, ISO14001).
• Drive Supplier PPM reduction initiatives and continuous improvement programs.
• Monitor and review supplier performance KPIs and initiate corrective actions.
• Responsible for supplier quality assurance activities including supplier evaluation, supplier selection support, supplier qualification, process validation, and supplier performance monitoring.
• Managed supplier quality performance during new product launches (NPD/NPI) and current production programs to ensure Right First Time (RFT) product launch.
• Conducted supplier process audits, PPAP audits, system audits, and product audits as per IATF 16949, customer requirements, and internal quality standards.
• Reviewed and approved PPAP documents including PFMEA, Control Plan, Process Flow, MSA, SPC, Capability Studies, IMDS, and dimensional/layout reports.
• Performed manufacturing feasibility assessments covering process capability, plant readiness, tooling, fixtures, capacity verification, and production process validation.
• Coordinated cross-functional teams including Purchasing, Product Engineering, Manufacturing, Program Management, Production Quality, and Suppliers to achieve project milestones and PSW targets.
• Supported Run-at-Rate trials, Production Readiness Reviews, and Facility Readiness evaluations to confirm supplier manufacturing capability and process maturity.
• Drove supplier development activities to improve Quality, Cost, Delivery (QCD), process capability, and manufacturing system effectiveness.
• Monitored supplier PPM, line rejection, customer complaints, warranty issues, and field failures, and implemented corrective actions to achieve zero-defect targets.
• Led root cause analysis and corrective action implementation using 8D, Why-Why, Fishbone, 5 Why, and CAPA methodologies for supplier and in-house quality issues.
• Coordinated ECN/PCN changes, deviation approvals, process changes, and engineering modifications with suppliers and internal cross-functional teams.
• Supported sourcing and purchasing activities through technical feasibility reviews, supplier risk assessment, and supplier costing evaluation discussions.
• Participated in cost negotiation and recovery discussions related to supplier quality issues, rejection recovery, sorting cost, rework cost, and continuous cost reduction initiatives.
• Ensured supplier compliance for process controls in welding (MIG/TIG/Spot), powder coating, machining, laser cutting, CNC bending, assembly, casting, moulding, stamping, painting, heat treatment, and surface treatment operations.
• Led containment actions, supplier escalation meetings, and supplier improvement plans for repeated quality concerns and delivery issues.
• Managed incoming inspection plans, calibration systems, gauge control, inspection records, NCR closure, and quality documentation as per ISO 9001 & IATF 16949 standards.
• Handled Incoming Quality Control (IQC) activities for sheet metal, fabrication, machining, casting, moulding, welding, electrical, wiring harness, and bought-out components as per drawing specifications, control plans, and customer standards.
• Implemented Kaizen, Poka-Yoke, Lean Manufacturing, 5S, and continuous improvement initiatives to reduce COPQ (Cost of Poor Quality) and improve operational efficiency.
• Coordinated customer audits, supplier visits, trial approvals, sample inspections, and production readiness reviews for new and existing suppliers.
• Customer Complaint Handling & Warranty Issue Management:
• Experience in tracking and validating warranty claims from customers and dealers.
• Skilled in warranty documentation management and approval process coordination.
• Ability to analyze warranty data, customer complaints, and failure trends for recurring issues.
• Knowledge of customer score analysis, customer PPM monitoring, claim rate, cost per unit, and failure frequency analysis.
• Skilled in 8D methodology, RCA, Why-Why Analysis, Fishbone Diagram, and structured problem-solving techniques.
• Ability to monitor warranty expenses and support cost reduction activities.
• Skilled in identifying high-cost components and implementing corrective and preventive actions (CAPA).
• Experience in preparing daily, weekly, and monthly MIS reports related to warranty claims, customer issues, and cost analysis.
• Proficient in Microsoft Excel and Power BI for dashboard preparation, reporting, and performance monitoring.
• Quality Assurance & Control – Proficient in various manufacturing processes, including: Sheet metal fabrication (pressing/stamping), welding – MIG/TIG, Projection, Spot welding, seam welding, machining, heat treatment, surface treatment, casting/molding, shot blasting / peening, powder coating, painting, cold forging threading/tapping, CNC machining, laser cutting, Punching, and CNC bending, assembly/testing and inspection.
• AIAG tool knowledge - Hardcore experience in implementation of 7QC Tools, Core tools SPC, MSA, FMEA, PPAP, APQP, ISO & IATF 16949, 4M Change Management, VDA 6.3, PDCA cycle, 8D, Kaizen, Poka-yoke, PFMEA, 5S & 3M, 6 SIGMA, risk management etc.
• Quality Professional Experience - Proven expertise in implementing quality methodologies (SPC, MSA, PSA, TQM, Six Sigma, Lean, APQP, PFMEA) to drive process control and quality excellence.
• Process Enhancement - Conducted process audit, product audit, system audits, dock audit and supplier audit for process enhancements. In-house PPM reduction, supplier PPM reduction by improving process at in-house & supplier’. Proficient in conducting supplier Audit as per VDA 6.3. Optimizing current product and processes.
• Tier 1 Automotive Supplier Experience - I have proven experience working with Tier 1 automotive suppliers from last 9+ years, leveraging expertise in QMS/IMS supply chain management, and manufacture to drive excellence and deliver high-quality components to leading OEMs. Ford, Volkswagen, Hyundai, Tata Motors, Mahindra & Mahindra, Force Motors, Mercedes-Benz, General Motors, Fiat, Knor-Bremse, JCB UK, TAFE, Cummins India Group.
• Experience & Skills - Proven experience in handling multiple automotive customers in India and globally. Strong knowledge and application of basic and advanced problem-solving tools, driving efficient issue resolution and continuous improvement.
• Interpersonal and Leadership Skills - Proven ability to build and maintain strong networks with customers and stakeholders.
• Excellent customer relationship management skills, driving satisfaction and loyalty.
• Effective leadership skills, inspiring teams and driving results-oriented performance.
• Duties and Responsibilities
• Quality Management System:
• Establish and maintain a robust Quality Management System (QMS) in accordance with OEM-specific standards and best practices including IATF 16949:2016 and ISO 9001:2015.
• Experience in continuous improvement activities related to Quality, Cost, Delivery, Safety, and Customer Satisfaction
• Create, maintain, and ensure adherence to quality documentation, including processes, procedures, policies, work instructions, and inspection reports, while providing training to process owners.
• Ensured compliance with Quality Management System (QMS) standards across all aspects, including audits, products, processes, layouts, and procedures, driving quality excellence and regulatory adherence.
• Managed and implemented quality management systems, ensuring strict adherence to local and global standards, including IATF 16949, ISO 9001, EMS 14001, and OHSMS 45001, as well as product-specific certifications and customer requirements, to guarantee product quality, safety, and compliance.
• I facilitate Management Reviews, maintain QMS documentation, track QMS KPIs, drive system-level improvements, and ensure departmental readiness for audits to uphold quality standards and regulatory compliance.
• Achieved flawless launch with no zero-km or warranty issues / field issue after SOP or IPC, ensuring customer satisfaction and product reliability.
• Collaborate with customer support teams to address customer feedback, complaints, and warranty claims related to product quality.
• Monitored customer scorecards to track performance, identify areas for improvement, and drive initiatives to enhance customer satisfaction, with the goal of winning customer awards.
• Audit and Compliance:
• Internal Audits: Conduct regular internal audits to ensure compliance with QMS /EMS / OHSMS requirements, identify areas for improvement, and verify corrective actions.
• External Audit Coordination: Collaborate with external auditors to facilitate audits, provide necessary documentation, and address any findings or concerns to maintain certifications.
• As an Auditor, I conduct internal audits, lead audits conducted by OEMs and certification bodies, ensure audit preparedness, and manage the closure of non-conformities (NCs) to maintain quality management system integrity.
• Maintained compliance with Customer CSR, CQI, VDA 6.3 process audit and JD standards throughout the value stream, ensuring adherence to industry and regulatory requirements.
• Led customer, second-party, corporate, and IATF audits, ensuring zero major and repeated non-conformities (NCs) through effective preparation, execution, and follow-up.
• Quality Control and Assurance:
• Define and execute quality control processes and inspection procedures across all production stages, including incoming materials, in-process checks, and final product inspections and control on Plant Metallurgy activities.
• Conduct regular audits to ensure compliance with quality standards and identify areas for improvement.
• Drive customer satisfaction by analyzing feedback, collaborating with the Division Head to implement improvements, and reducing parts per million (PPM) defects internally and at the customer's end, ultimately enhancing product and process quality.
• Implemented a robust quality gate process to catch defects before products shipped to customers post-SOP / IPC Initial production control, resulting in a significant reduction in warranty claims and improved customer satisfaction.
• Coordinate necessary containment with CFT in the event of issues identified in the shop floor or at customer end.
• Continuous Improvement / Kaizen:
• Lead and facilitate continuous improvement initiatives and promote the quality culture, such as Poka-Yoke, Quality tools, Layered Process Audits, to enhance product quality, process efficiency, Six Sigma, 5’S, Kaizen, TPM, and overall performance and eliminate or reduce the waste opportunity.
• Led organization-wide quality culture improvement initiatives, driving a mindset shift towards quality excellence and ensuring long-term sustenance aligned with quality objective and customer requirements.
• Taken initiatives with utilizing of customer feedback and Employee Suggestion through suggestion scheme to driven improvements in internal PPM and customer PPM reduction.
• Process enhancement and Documentation:
• Designed and developed process maps, flowcharts, and work instructions using tools like turtle diagram.
• Ensured process the process objectives or KPI are maintaining and monitoring metrics like PPM, COPQ, FTR etc.
• Initiated and led projects to improve First-Time Quality (FTQ) / First time right (FTR) and reduce scrap costs, utilizing methodologies like 8D, 5 Whys, and Six Sigma, resulting in significant improvements.
• Ensured shop floor quality by verifying product and process conformity to established standards.
• Enhanced production efficiency and reduced waste through effective resource management, resulting in improved FTQ and cost savings.
• Non-Conformance Management:
• Conduct thorough investigations into root causes of quality issues and collaborate with cross-functional teams to implement preventive measures using tools like 8D, 5Why, Fishbone, PDCA, and SWOT Analysis etc. related to supplier, in-house, customer complaints, warranty issues, and field failures.
• Managed customer complaints from receipt to closure, ensuring timely resolution, stakeholder engagement, and follow-up monitoring to prevent recurrence.
• Resolved customer complaints and ensured close-loop implementation of identified Corrective Actions (CA) and Preventive Actions (PA) to prevent recurrence.
• Training and Awareness to Quality Team:
• Identified training needs as per the training procedure and developed competency-building initiatives to enhance the quality team’s skills and knowledge.
• I delivered training sessions to employees on quality standards, procedures, and tools, fostering a culture of quality across the organization and empowering teams to identify and address quality-related issues.
• Actively participate in cross-functional quality improvement initiatives, driving collaboration and innovation to achieve quality goals and objectives.
• Customer Liaison:
• Represent the organization in Certification audit, third party audits, customer audits and meetings, ensuring effective communication and building strong relationships.
• Coordinated with the customer to obtain approval for a running change to update a product's material, ensuring minimal disruption to production and maintaining quality standards.
• Led safety and regulatory issue resolution, serving as a single window contact for internal and external communication and coordination.
• Collaborated with internal teams, external suppliers, and regional stakeholders and globally to deploy quality management standards, ensuring alignment and compliance across the organization.
• PROFESSIONAL ACHIEVEMENTS
• Successfully Implemented ISO 9001:2015, IATF 16949:2016 and PSA (NSA system).
• Certifications:
• IATF 16949:2016 & ISO 9001: 2015 Certified Internal Auditor.
• Quality Core Tool (APQP, FMEA, MSA, SPC, PPAP, Control Plan) certified.
• Lean six sigma green belt certified.
• Stellantis –CSRO3 Quality manual training certification.
• A1 German language Certified.
• Power BI.
• SAP PP & QM.
• TQM- Total Quality Management & DWM.
• Awards and Recognition:
• Multiple Appreciation Certificates for quality, innovation, and cost savings
• 1st prize in Remsons group for conducting maximum training.
• Conducting 5S audit and start best 5S audit area & Best Kaizen Prize distribution in monthly meeting.
• Developed DOJO Room&Company overview gallery.
• Participating & presenting in ACMA & got 1st prize in ACMA QC circle competition -2023.
• 1st prize in “Dipex - 2013” state level project competition.
• Attending external SPC, APQP, MSA, PPAP & VDA PFMEA training conducted by BSI.
• Quality and Process Improvements:
• Reduced child missing complaints by 80%
• Implemented DOJO training
• Enhanced supplier quality through audits.
• Supplier Development:
• Successfully executed supplier audits and evaluations
• Trained suppliers on APQP, PPAP, FMEA, MSA, and SPC