Ramesh Sonar

Senior Production, and Quality professional with over 30 years of progressive leadership across appliance manufacturing, injection moulding, electrical kitchen appliances, and e-commerce fulfilment packaging. Demonstrated expertise in managing end-to-end plant operations, assembly lines, dispatch logistics, quality inspection protocols, and vendor quality management. Skilled in ISO 9001 systems, Kaizen, 5S, CAPA, Root Cause Analysis (RCA), and line balancing, combined with modern adoption of Generative AI tools (ChatGPT, Gemini) to optimize workflow documentation, reporting, and shop-floor productivity.

Proven track record of scaling dispatch throughput for major platforms like Amazon while maintaining strict defect-free standards.

Quality & Production Manager – Cooler Department - Rishika Industries - Bhilad

(2026-03 - 2026-05)

• Led quality and production operations for the cooler manufacturing department, ensuring adherence to production targets, product specifications, quality standards, and customer requirements.
• Oversaw production planning, shop-floor activities, quality inspection, process control, and coordination between production, quality, maintenance, and supporting teams to ensure smooth and efficient manufacturing operations.
• Drove continuous improvement initiatives through rejection analysis and Root Cause Analysis (RCA) to reduce defects, improve production efficiency, and strengthen overall product quality.

Cooler Assembly In-charge - Jalaram Polymer Pvt. Ltd. - Daman

(2023-01 - 2026-02)

• Managed plant production and quality operations while ensuring compliance with ISO requirements, process standards, and customer specifications.
• Oversaw production planning, preventive maintenance scheduling, procurement of spare parts, and process improvement activities to support efficient plant operations.
• Implemented continuous improvement initiatives including Kaizen, 5S, CAPA, and Root Cause Analysis to reduce defects, improve production throughput, and strengthen process quality.

Cooler Assembly In-charge - National Plastic Industries Ltd. - Dadra

(2016-12 - 2022-12)

• Led assembly and quality control teams for the manufacturing of air coolers and home appliances while maintaining production and quality standards.
• Performed inward inspection of plastic moulded parts, sheet metal components, and electrical motors while maintaining ISO-standard inspection documentation.
• Analysed market return goods, prepared quality reports, and coordinated corrective actions with production teams and vendors to address recurring quality issues.
• Drove 5S and Kaizen activities at the shop-floor level to improve process standardisation, workplace organisation, and operational efficiency.

Quality Assurance - Canbara Industries Pvt. Ltd. - Silvassa

(2009-12 - 2016-12)

• Managed in-process inspection, final inspection, vendor audits, and quality documentation in accordance with ISO 9001:2008 requirements.
• Conducted material testing for injection moulded parts and ensured quality compliance for outsourced job work and production components.
• Prepared process and customer samples while monitoring daily rejection rates and line-control quality metrics to support continuous improvement.

QC In-charge - S.S. Appliances - Murbad (Thane), Mumbai

(2008-04 - 2009-12)

• Inspected sheet metal components, plastic moulded parts, and electrical motors to ensure compliance with defined quality standards.
• Prepared inward inspection documentation according to ISO requirements and conducted final inspection and quality audits of finished goods for domestic and export supply.

QC Supervisor - K Tejas Co. - Sion, Mumbai

(2006-03 - 2008-12)

• Supervised quality control operations and maintained inspection records for production activities.
• Supported final quality audits and verification of finished products before dispatch, ensuring adherence to established quality requirements.

QC In-charge - Comfort Coolers Pvt. Ltd. - Murbad (Thane)

(1994-01 - 2005-05)

• Supervised quality assurance and final inspection of finished products including air coolers, tower fans, and electrical mixers for domestic and export markets.
• Maintained quality documentation and ensured compliance with product quality standards throughout production and before final dispatch.

Diploma - Mechanical Engineering - DVIIT, Aurangabad