Vinay Kumar

A result-oriented professional with over 16 years of experience in Quality Assurance and Quality Control, Supplier and Customer Quality Management, and the implementation of Quality Standards and Procedures, ensuring accurate execution of customer requirements and effective monitoring of manufacturing processes. Adept at quality management, process improvement, and automation within reputed organizations, with hands-on expertise in multi-disciplinary, multi-product environments. Skilled in devising and implementing innovative production planning and control procedures and well-versed in Drawing and Manufacturing Processes, operational strategies for quality functions, Training activity 5S and TPM activities.

Possesses strong exposure to implementing processes, WI, SOPs, and quality documentation, with a comprehensive understanding of FMEA, and 8D, CAPA standards, focused on creating safe and productive work environments. Demonstrates a proven track record of streamlining workflows and establishing effective SOPs to enhance productivity. Experienced in Lean Manufacturing, Katzen, and other quality enhancement methodologies, with an impeccable record of driving continuous improvement initiatives.

A dynamic leader, skilled at directing cross-functional and multicultural teams through interactive and motivational leadership to optimize resource utilization and achieve operational excellence.

Assistant Manager – Quality Assurance / Production Department - Eastman Auto Power I Ltd. - Baddi, Himachal Pradesh

(2023-05)

• Serve as Section Head for Charging Manufacturing Processes, leading the Quality Assurance team in handling in-process QA functions.
• Monitor and control charging operations by strictly adhering to standard operating procedures and quality standards.
• Conduct detailed analysis of warranty and charging failures, identifying defects and implementing corrective and preventive actions.
• Develop defect galleries and defect matrices to enhance operator understanding and training.
• Prepare cumulative quality reports and provide actionable insights to senior management.
• Draft and maintain product specifications, One Point Lessons, Work Instructions (WI), Standard Operating Procedures (SOPs), Process Flow Charts, 8D, and Control Plans.
• Promote customer requirements, manage documentation, and coordinate internal and external audits, including Mahindra & Mahindra.
• Perform Root Cause Analysis (RCA) to drive improvements in product quality and minimize process rejections.
• Handle customer complaints promptly, ensuring root cause identification and immediate resolution.
• Generate and review daily and weekly MIS reports with Plant Head and Department Heads.
• Lead initiatives for Process Excellence by addressing non-conformities in both process and product.
• Conduct internal revalidation of processes both statistically and performance-wise, ensuring consistency across models.
• Analyze customer quality issues using 8D methodology and drive corrective action reviews with management and CIT teams.
• Act as Team Leader in Quality Improvement Projects (QIPs), guiding problem-solving initiatives through Kaizen.
• Conduct training sessions for quality and production employees to reinforce best practices.
• Foster cross-department collaboration to enhance productivity and improve quality.
• Lead, mentor, and monitor team performance to ensure operational efficiency and continuous improvement.
• Experienced in production planning activities, job allotment, and record keeping.
• Monitoring to plan / slow-moving inventory.
• Working with the procurement department in material planning and analysis to reduce inventory level.

Officer – Technical Department - Luminous Power Technologies Pvt. Ltd. - Haridwar

(2021-12 - 2023-05)

• Led QA operations for multiple sections, including Spine Casting, Grid Casting, Pasting, Curing Chambers, Ball Mill Operation, Assembly, Acid Filling, Charging, and Pre-Dispatch Inspection (PDI).
• Implemented Statistical Process Control (SPC).
• VRLA operation for multiple sections, including grid casting, pasting, curing, plate formation, 100% plate wt., assembly, charging section & final dispatch.
• Actively contributed to VRLA battery development projects for international markets by interfacing with customers and developing customized processes and products.
• Conducted regular process audits and initiated trials for alternative raw materials to improve product performance.
• Developed packaging material standards and established Pre-Dispatch Inspection criteria to streamline production batches.
• Conducted internal revalidations of processes using statistical methods and performance benchmarks, ensuring cross-model consistency.
• Acted as OAM PILLAR TPM In-Charge and served as Plant Coordinator for Quality Circle and TQM initiatives.
• Led warranty failure analyses and participated in market surveys to identify trends in customer complaints.
• Controlled internal and external rejection rates in Motorcycle Battery Assembly processes through proactive quality control measures.
• Prepared MIS and technical reports for senior management review.
• Collaborated with OEMs to address customer complaints and drive new product development initiatives.
• Ensured on-time delivery and zero-line stoppages for OEM customers through effective quality and logistics coordination.
• Operated SAP QM Module for quality tracking and maintained Bill of Materials (BOM) updates.
• Managed internal documentation control, including Quality Manuals, Department Manuals, and Work Instructions aligned with customer requirements.

Junior Officer – Technical Department - Luminous Power Technologies Pvt. Ltd. - Garget

(2010-04 - 2021-12)

Quality & Production Supervisor - Appu International Ltd. - Ludhiana

(2009-07 - 2010-03)

Cycle Parts Manufacturing Company

• Reviewed, updated, and maintained specifications, work guides, and SOPs to ensure consistent product quality.
• Conducted root cause analyses to address daily rejections in Injection Molding processes.
• Developed and optimized Injection Molding processes to improve yields and reduce rejection rates.
• Prepared daily and monthly rejection reports, analyzing trends and recommending corrective actions to Higher management.
• Managed First Piece and Last Piece inspections at each stage of production.
• Led Poka-Yoke and Kaizen initiatives to drive continuous process improvement.
• Coordinated with cross-functional teams (CFT) to promptly resolve quality-related issues.
• Monitored key performance measures online and implemented corrective actions to meet production quality standards.

Diploma - Mechanical Engineering - C.T. Polytechnic College (2012 - 2012)

Secondary Education - 10th Grade - Government High School (2005 - 2005)