Prashant Sonaje

Manufacturing Quality Assurance and Quality Control leader with 18+ years of experience across FRP/GRP composites, wind turbine blades, PU foam, PVC films and polymer-based products.

Currently General

Manager – QA/QC at EPP Composites, leading quality activities across multiple manufacturing units. Experienced in QMS/IMS implementation, incoming/in-process/final inspection, supplier quality, customer and third-party inspections, audit management, material traceability, nonconformance management, root-cause analysis, CAPA and continuous improvement. Technical foundation in Plastics and Polymer Technology, with a practical, risk-based approach to process control, defect prevention, customer satisfaction and team development.

General Manager – QA/QC | Quality Head – All Units at EPP Composites Pvt. Ltd. (2026-06 – Present)

• Lead QA/QC activities across multiple manufacturing units producing FRP/GRP composite products, aligning inspection and process controls with approved drawings, specifications and customer requirements.
• Drive implementation and standardization of the Integrated Management System, quality procedures, audit programs, risk controls and continual improvement activities.
• Oversee incoming, in-process and final inspection, material identification and traceability, inspection records, test reports and product release controls.
• Monitor product conformity, first-time-right performance, rejection/rework, nonconformities and customer complaints; coordinate RCA and CAPA with production, engineering, stores and supply chain.
• Lead customer, third-party inspection and certification audits, ensuring timely action closure and evidence-based effectiveness checks.
• Strengthen documentation, competency development, inspection planning and quality reporting to improve audit readiness and prevent quality escapes.
• Ensure compliance with applicable ISO, EN, ASTM, ASME and customer-specific requirements.

Manager – Quality Control (FRP) at Metso India Pvt. Ltd. (2022-04 – 2026-03)

• Led quality control and supplier quality activities for FRP equipment manufacturing and supported quality assurance for international projects.
• Conducted supplier audits, quality surveillance and compliance assessments; coordinated with engineering, design and sourcing teams.
• Managed nonconformance reporting and closure, manufacturing documentation, traceability and process improvement activities.
• Coordinated customer and third-party inspections to verify conformity with approved specifications and applicable international standards.
• Supported delivery of FRP equipment for projects in the USA, Egypt, South America and Kazakhstan.
• Strengthened the supplier audit framework, with a reported 20% improvement in supplier compliance; improved NCR response time and documentation accuracy.

Senior Manager – Quality Assurance at Inox Wind Ltd. (2021-11 – 2022-04)

• Oversaw QA/QC activities for 55.3-metre wind turbine rotor blades.
• Led inspections, defect analysis and raw-material qualification to support product conformity.
• Improved Quality Assurance Plans for critical manufacturing processes and supported customer approval readiness.

Manager – Quality at Reliance Composite Solutions (2019-07 – 2021-11)

• Managed QA/QC for 63.7-metre wind turbine blades, including process compliance, inspection and quality documentation.
• Led Integrated Management System certification activities and supplier audits.
• Supported first-blade process validation through dimensional measurement, inspection and analysis against customer requirements.
• Served as plant safety representative, coordinating compliance activities with the central safety team.
• Achieved ISO 9001, ISO 14001 and ISO 45001 certifications; secured DNVGL-SE-0436 Blade Shop Approval.
• Reduced NCR closure cycle time by 25%.

Senior Engineer – Production Quality at Vestas Wind Technology India Pvt. Ltd. (2016-08 – 2019-06)

• Completed three-month wind-blade technology and quality training in Windsor, USA.
• Helped establish the finishing and NDT section for wind blades in alignment with production takt-time requirements.
• Monitored process documentation and quality data through QDA and SAP; generated monthly quality MIS reports.
• Served as an NC approver for the V110 product line and supported customer inspections for blade approvals.
• Managed quality-tool records through the EAM system, including calibration and maintenance tracking.
• Contributed to the Ahmedabad plant receiving the Vestas Global Quality Race Award.

Assistant Manager – QA at Kurl-on Enterprise Ltd. (2015-04 – 2016-07)

• Reduced mattress rejection from 22% to 5% through quality improvement and process control activities.
• Reduced PU foam laboratory failures from 29% to 5%.
• Implemented ISO 9001 practices, CAPA and critical-to-quality (CTQ) parameter analysis.

Engineer – Quality Assurance at Wind World India Ltd. (2009-01 – 2015-04)

• Improved wind-blade quality rating from 7.5 to 8.0 out of 10.
• Led a Six Sigma project that reduced hazardous waste per blade by 14%, generating reported savings of ₹29.8 lakh.
• Executed vendor qualification, supplier/process audits and manufacturing quality activities.

QA Engineer at Suzlon Energy Ltd. (2007-11 – 2008-12)

• Contributed to delivery of Suzlon’s first “Zero-NC Blade”.
• Supported trials and quality validation for sandblasting and spray-painting processes.

Senior Executive – QA at Caprihans India Ltd. (2007-01 – 2007-10)

• Managed quality control for PVC films, including raw-material testing and shade development.
• Strengthened quality checks to improve product reliability and reduce customer complaints.

B. Tech in Plastics & Polymer Technology – Laxminarayan Institute of Technology, Nagpur (2006)

Diploma in Plastic Engineering – Government Polytechnic, Nashik (2003)