Yoge G. Jirafe

Key Responsibilities:

• Heading: Overall Development Quality Function for Varroc Polymer BU (all Polymer Plants in India).
• RFQ Review: Evaluate from quality perspective to enhance product quality and ensure compliance with customer-specific requirements.
• Customer Liaison: Handle rejections, preventive/corrective actions, and ensure flawless 4W project launches.
• Quality Planning: Sign-off on Quality Plans, Gauges, and DVP requirements per customer standards.
• Testing Facilities: Plan and establish labs for Mirrors, Seats, and Body parts.
• Homologation: Coordinate with ARAI for certification of Mirrors & Seats; perform COP & E-certification audits.
• QMS Implementation: Drive Gate Review system, PFMEA reviews, SOP readiness audits, and CFT interactions.
• Customer Complaints: Address built concerns, resolve issues effectively, and conduct firewall inspections when required.
• Supplier & In-house Quality: Monitor SOP + 3 months quality, coordinate with CFT for closure of concerns.
• PPAP & Approvals: Conduct customer PPAPs and manage approvals

Key Responsibilities:

• Project Execution: Lead new product development including debugging, process validation, PPAP, DFQ, material selection, customer approvals, master sample sign-off, and AAR approvals.
• Design Stage Reviews: Conduct technical reviews at design stage to ensure quality integration.
• QA/QC Management: Oversee quality assurance and control processes across entire project lifecycle.
• Craftsmanship Improvements: Drive fit & function enhancements and evaluate color/texture of components.
• PPM Reduction: Monitor and implement action plans to reduce PPM of development parts at SOP.
• Flawless Launch: Plan and execute activities for defect-free SOP launches; conduct QA audits.
• Inspection Systems: Establish and monitor Firewall, EPC, and GP12 inspections.
• QMS Implementation: Set up and monitor quality management systems for project execution.
• PFMEA: Conduct reviews and implement action plans for RPN reduction.
• Fixture Development: Manage concepts, design approvals, and final R&R approvals for checking fixtures.
• Process Validation: Validate advanced techniques (IMD, thermo casing/gaining, vibration welding, ultrasonic welding, laser cutting).
• Component Validation: Validate molded, painted, electroplated components; conduct HVPT and tool buy-offs.
• Customer Complaints: Handle complaints for regular and new components; implement improvement projects.
• Supplier Assistance: Provide technical support during product development aligned with customer requirements.
• DVPR Testing: Execute product validation testing per customer requirements.
• Engineering Changes: Implement changes focused on cost optimization and quality improvements.
• Audits: Conduct internal TS audits and self-assessments.
• Continuous Improvement: Establish and practice structured quality improvement approaches.
• Internal TS audits, self-assessment audits, and customer-specific quality assurance audits.
• Adherence to customer PPAP and DVPR requirements.
• Checking fixture development and approvals for bumper, dashboard, door trim, and other trim components.
• Mold trials, joint checks with customers, and tool buy-offs for bumper, dashboard, doors, and interior parts.
• Successfully completed 100+ projects for various customers in India and abroad.
• Delivered consistent quality improvements aligned with customer complaints and evolving requirements.
• Established robust QMS practices and inspection systems ensuring flawless SOP launches

Key Responsibilities:

• New Enquiry Handling: Conduct feasibility studies, capture Voice of Customer, and align requirements with development capabilities.
• APQP Management: Prepare and monitor timing charts, coordinate activities with cross-functional teams (CFT).
• Project Coordination: Drive new product development from initiation to quality sign-off.
• Tooling & Materials: Oversee development of jigs, fixtures, gauges, raw materials, and bought-out parts (BOPs).
• Technical Issue Resolution: Collaborate with Marketing and Customers to resolve design and process challenges.
• Design Reviews: Conduct DFMEA, product design reviews, and tool maker reviews.
• Process Validation: Validate processes and resolve FTN issues during vehicle trials.
• Engineering Changes: Execute changes with focus on cost optimization and quality improvements.
• Customer Quality Systems: Implement and adhere to customer-specific quality requirements.
• Inspection Systems: Establish and monitor Firewall, EPC, and GP12 inspections.
• PFMEA: Review and implement action plans for RPN reduction.
• Fixture Development: Manage checking fixture concepts, design approvals, and final R&R approvals.
• Validation Activities: Conduct process validation for molded, painted, electroplated components; manage HVPT and tool buy-offs.
• Complaint Handling: Address customer complaints for regular and new components; initiate improvement projects.
• Supplier Assistance: Provide technical support during product development in line with customer requirements.
• DVPR Testing: Execute product validation testing per customer requirements.
• Audits: Conduct internal TS audits and self-assessment audits.
• Continuous Improvement: Establish and practice structured quality improvement approaches

Key Responsibilities:

• Mold Development: Led development of molds for coolers, mixers, water purifiers, and vacuum cleaners.
• Fitment Trials: Conducted product fitment trials and executed modification activities for new molds.
• Mold Trials: Initiated actions and approvals for new molds; established molding cycle, weight, color, and aesthetics for plastic components.
• Material Trials: Conducted trials of plastic raw materials and master batches for diverse applications.
• Supplier Evaluation: Performed technical evaluation of subcontractors for plastic components and raw materials.
• Quality Systems: Implemented corrective action plans for non-conformities; controlled rejections and scrap.
• Documentation: Prepared ISO audit documentation and supplier evaluation reports.
• Product Portfolio: Supported manufacturing and marketing of washing machines, air conditioners, air coolers, mixer-grinders, microwave ovens, vacuum cleaners, and water purifiers.
• Established 115 molds with only 0.5% incoming rejection level across suppliers.
• Reduced rejection rates from 8% to 2%, significantly improving quality and cost efficiency.
• Successfully launched 6 kitchen appliance projects (coolers, food processors, water purifiers).
• Played a key role in cost reduction of molded components.
• Rationalized supplier base to achieve further cost optimization

Key Responsibilities:

• Process Monitoring: Set, maintain, and monitor process parameters to ensure stable production quality.
• Machine Setup: Prepare molds and machines for production runs.
• Production Planning: Plan activities to meet production schedules and targets.
• Issue Detection: Identify process or equipment malfunctions and initiate corrective actions.
• Mold Trials: Conduct new mold trials, plan tool corrections, and execute modifications.
• Tool Inputs: Provide technical inputs for tool corrections and modifications to achieve required results.
• Customer Supply: Manufacture and supply automotive components to Bajaj Auto Ltd

Key Responsibilities:

Setupet Process Parameters

Define and monitor process parameters to ensure consistent production quality.

• Identify key process variables (temperature, pressure, cycle time)
• Record baseline values for repeatability
• Continuously monitor and adjust during production

Ensure molds and machines are correctly set up for production runs.

• Install molds securely in the machine
• Verify alignment and clamping force
• Run initial test cycles to confirm setup

CriticalDetect Malfunctions

Identify process or equipment issues early to minimize downtime.

• Monitor machine performance indicators
• Inspect parts for defects (flash, short shots, warpage)
• Log and escalate abnormalities

Run trials for new molds to establish stable production cycles.

• Perform initial trial runs with sample parts
• Measure cycle time, weight, and aesthetics
• Document trial results for approval

Provide inputs for tool modifications to achieve required results.

• Review trial data with toolmakers
• Suggest corrections for dimensional accuracy
• Validate changes with re-trials

OutcomeSupply to Customer

Manufacture and deliver automotive components to Bajaj Auto Ltd.

• Ensure parts meet customer specifications
• Maintain delivery schedules
• Track quality metrics for customer satisfaction