Kanukula Nikhilesh

Experienced Supplier Quality Engineer with over 7 years of experience in automotive quality assurance, supplier management, and compliance. Skilled in implementing and maintaining ISO 9001, IATF 16949, and APQP frameworks to ensure supplier alignment with customer-specific requirements. Demonstrated expertise in supplier audits, PPAP validation, FMEA, and 8D-based problem resolution, driving measurable improvements in supplier performance and product quality.

Adept at leveraging data analytics and cross-functional collaboration to enhance supply chain reliability and support continuous improvement initiatives. Willing and available to travel internationally (up to 30%) to support off-shore manufacturing partners and production readiness activities.

Sr Supplier Quality Engineer at Brose North America (2025-01 – Present)

• Engineered, developed, and continuously improved high-volume manufacturing and automated assembly processes for automotive mechatronic components, including WD74/75 Door Module programs, supporting Just-in-Time (JIT) production for OEM customers such as Ford, General Motors, Honda, BMW, and Stellantis.
• Partnered with cross-functional Engineering teams (Mechanical, Electrical, and Test Engineering) throughout the New Product Introduction (NPI) lifecycle, from design validation through mass production ramp-up.
• Led quality assurance and process engineering activities for automated assembly and welding lines supporting WD74/75 Door Modules, improving Overall Equipment Effectiveness (OEE), First Time Quality (FTQ), process capability, and manufacturing efficiency while reducing scrap, warranty claims, and customer defects.
• Planned, executed, and presented statistical investigations using Minitab, applying Pareto Analysis, Process Capability (Cpk/Ppk), Gage R&R, Analysis of Variance (ANOVA), and Design of Experiments (DOE) to identify root causes and implement data-driven corrective and preventive actions.
• Applied Root Cause Analysis (RCA), DMAIC, PDCA, Reverse PFMEA, Red X Shainin, and 8D methodologies to resolve manufacturing, assembly, and customer quality issues across high-volume production programs.
• Utilized Statistical Process Control (SPC) principles to monitor process performance, reduce variation, improve process capability, and support continuous improvement initiatives.
• Developed and maintained Product Quality Plans (PQP) to define quality gates, inspection criteria, and control strategies across new program launches.
• Conducted periodic reviews of Field and Factory Quality Data — including production performance, customer claims, warranty data, scrap trends, and audit findings — using SAP QM, SharePoint QIM, GECOS, and Minitab to drive data-based decision-making with OEM partners
• Supported APQP deliverables, PFMEA development, Control Plans, capability studies, equipment releases, and engineering change implementation throughout new product launches and serial production.
• Generated monthly Product Health summaries consolidating scrap trends, warranty claims, audit findings, and process capability data for leadership review.
• Monitored Outgoing Quality Control (OQC) metrics and supported Customer Audit (CA) readiness at supplier and OEM sites to ensure conformance ahead of shipment.
• Supported new product development builds and pilot runs, coordinating with DFx/DFm engineering to identify and resolve manufacturability and assembly issues early in the design cycle.

Supplier Quality Engineer at ThyssenKrupp North America (2023-10 – 2025-01)

• Acted as the lead SQE for CAT C16 and Cummins Titanium Series crankshaft programs, ensuring supplier adherence to customer-specific requirements, PPAP documentation, and statistical capability benchmarks
• Functioned as the key quality systems lead to produce CAT C16 and Cummins Titanium Series crankshafts, rigorously adhering to customer-specific requirements, automotive quality standards, and statistical capability requirements.
• Utilized Certified Quality Auditor (CQA) expertise to conduct internal process audits, customer audits (CAT & Cummins), and third-party assessments, driving resolution of nonconformances using 8D and other structured problem-solving tools.
• Collaborated with offshore and domestic supplier manufacturing sites to align on PQP requirements, inspection standards, and capability benchmarks ahead of production release
• Led PPAP documentation and approval processes for new and modified product lines, preparing FMEAs, Control Plans, and MSA studies collaboratively with engineering, and supporting change management activities.
• Monitored and analyzed Critical-to-Quality (CTQ) characteristics during machining and finishing operations using SPC and statistical analysis, upholding dimensional and metallurgical standards.
• Conducted comprehensive root cause investigations deploying tools such as Fishbone and 5-Why to address internal and customer issues, reinforcing a deep understanding of a Quality Management System.
• Supported supplier quality initiatives via incoming inspection and audit readiness for raw materials and forged components, ensuring compliance with automotive production standards.
• Ensured audit readiness and strict adherence to CAT's Supplier Quality Excellence Process (SQEP) and Cummins-specific frameworks, while leading cross-functional meetings on quality gate checks.
• Facilitated training and certification for operators and technicians in inspection techniques and Control Plan implementation, thus reinforcing quality practices and warranty claim support.
• Triaged and resolved quality-critical issues at OEM (CAT, Cummins) and supplier sites, driving root-cause corrective actions under tight production timelines

Software Quality and test engineer at Waymo (2021-11 – 2023-08)

• Conducted large-scale data analysis on autonomous driving logs to evaluate ADAS system performance, including perception accuracy, object tracking, and path planning consistency.
• Developed interactive dashboards and visualizations in Power BI and Tableau to monitor key quality metrics (e.g., disengagement rates, critical event frequency, system latency) across test fleets.
• Used SQL and custom data queries to extract structured data from cloud-based storage and telemetry platforms for analysis and reporting.
• Automated data ingestion and analysis pipelines to evaluate functional behavior across scenarios such as unprotected turns, pedestrian detection, and emergency braking.
• Collaborated with software and safety teams to define and monitor KPIs for regression testing, simulation performance, and release validation.
• Performed root cause analysis on anomalies in autonomous vehicle behavior by correlating structured and unstructured sensor data from LiDAR, radar, and camera systems.
• Utilized Excel (Power Query) and Python (for backend scripting) to support ad hoc investigations and build flexible data models for scenario-based insights.
• Applied data forensics techniques to correlate structured and unstructured sensor data (LiDAR, radar, camera) with system anomalies, translating findings into executive-level quality and program health reporting
• Generated executive-level reports summarizing system health, quality trends, and ADAS feature performance over time, supporting cross-functional reviews and go/no-go decisions.

Project Engineer (DRE) at Mahindra and Mahindra Limited (2016-04 – 2018-12)

• Served as the Design Responsible Engineer (DRE), managing complete lifecycle of assemblies from conceptual design to production release and customer delivery.
• Coordinated with cross-functional teams including design, manufacturing, quality, and procurement to ensure timely and cost-effective execution of complex aerospace projects.
• Directed the creation and validation of engineering documentation such as DFMEA, DVP&R, 2D drawings, 3D CAD models, BOMs, and GD&T annotations.
• Applied root cause analysis (RCA) and implemented corrective and preventive actions (CAPA) to resolve design, manufacturing, and field issues.
• Utilized tools such as SolidWorks, Creo, and AutoCAD for modeling precision Automotive components and assemblies.
• Liaised with suppliers for build-to-print and custom manufacturing of Engine and gear components, ensuring conformance to technical specifications and quality standards.

Master's in Data and Industrial Engineering – University of Michigan - Rackham Graduate School (2019-01 – 2021-12)

Bachelor's in Mechanical Engineering – JNTUH, India (2011-06 – 2014-09)