George Sunny Kadavan
Kitchener,ON
Summary
Detail-oriented QA Engineer with over 5 years experience in the Quality assurance, food packaging industry, specializing in injection molding. Demonstrated expertise spans the Production, Testing, and Quality realms of engineering. Possessing proven proficiency in Continuous Improvement, PPAP, PFMEA, 8D Problem Solving, CARs, Root Cause Analysis, Control Plans, HACCP and Quality Function Deployment (QFD). I bring robust knowledge in implementing ISO 9001, FSSC 22000 and ISO TS 16949 standards, emphasizing a commitment to maintaining high-quality benchmarks. Additionally, I command a solid working knowledge of MS Office, MS Excel, Minitab, Cyframe(ERP). Beyond technical competencies, my skill set includes excellent team management and communication abilities. Strong ability to collaborate with cross-functional teams to develop and optimize quality control processes.
Overview
7
7
years of professional experience
1
1
Certificate
Work History
Quality Engineer
E.Hofmann Plastics
Orangeville, ON
04.2022 - Current
- Established direct communication channels with customers, ensuring a streamlined process to develop and deliver products that consistently meet or surpass their requirements
- Conducted root cause analysis and executed corrective and preventive actions to address process-related concerns and customer complaints, contributing to the continuous improvement of operational efficiency and customer satisfaction
- Initiated and led on-site visits in response to customer complaints, meticulously analyzing issues to gain a comprehensive understanding of customer processes, fostering effective issue resolution and enhancing overall customer experience
- Collaborated with the Quality Manager in the establishment, implementation, and maintenance of the quality management system, contributing to the overall enhancement of operational efficiency
- Actively interfaced with Engineering Managers and Operations to ensure the seamless launch of new products for production, emphasizing effective cross-functional communication
- Provided comprehensive support and training to Quality Technicians, ensuring strict compliance with the relevant requirements of the quality management system for both products and processes
- Support and assign the activities to R&D technician and evaluating the results
- Develop and manage HACCP plans to identify and control food safety hazards throughout the production process
- Conducted internal audits, to assess compliance with FSSC requirements
- Proficiently closing out findings, creating detailed audit reports, and determining appropriate corrective and preventive actions to bolster quality processes
- Analyzed failure, corrective, and preventive actions in response to customer complaints, demonstrating a commitment to addressing customer concerns and improving overall satisfaction
- Conduct weekly management meeting for customer complaint evaluation
- Created and maintained company quality documentation, including quality manuals, procedures, and work instructions, ensuring compliance with industry standards
- Engage actively in the testing process for new product launches
- Utilized Minitab for process capability analysis on new products and machines, contributing to data-driven decision-making in product development
- CMM programming (PC-DMIS) for all products in production
- Responsible for planning, organizing, and managing the overall activities of receiving/outgoing quality functions
- Continuously improving QA receiving inspection processes and procedures
- Collaborated with suppliers to ensure the quality of incoming materials and components
- Ensured the timely resolution of supplier failures, corrective actions, and preventive measures
- Generated comprehensive reports on quality metrics and performance for management review, providing valuable insights for strategic decision-making.
Quality Technician
The Hi-Tech Gears Canada
Guelph, ON
09.2020 - 04.2022
- Responsible for ensuring that QMS procedures and work instructions are being followed as well as Safety policies & practices on the production floor
- Manages any owned procedures in accordance with the Quality Management System
- Conduct daily production line reviews to ensure compliance with current work instructions/Inspection guidelines
- Detect non-conforming product at any stage in the process and assist production in the identification, containment, sorting/rework and disposition of the product
- Make suggestions to improve or refine existing process controls
- Proficient in Operating CMM, Jenoptik and Contracer to evaluate product conformance
- Create, train and monitor quality alerts, Work instructions, special instructions and use/care of provided inspection gauges
- Work together with production on creating and improving all operator and inspection instructions
- Create, document and train operators on machining and material boundary samples
- Evaluate and decision 'First Off' parts to customer and/or internal requirements
- Assist in identifying potential root causes and possible corrective actions
- Conduct measurement analysis for capability studies, GR&R and review data for accuracy.
Jr. Quality Engineer
DBG CANADA LTD
Mississauga, ON
07.2017 - 04.2020
- Followed quality documentation according to established quality manual and procedures
- Conducted visually and dimensional verifications of in parts and finished parts for completeness to customer requirements
- Ensured that the first off, frequent checks, and last off are being completed as per the Inspection Plan requirement
- Ensured that all the relevant inspection documentation are available at the cell and are being followed as per the Process Audit matrix
- Ensured that the operator is properly trained and certified to run the part as per the skill matrix
- Ensured that any interruption in the production was handled as per the bin and tote cover procedure
- Ensured that the containers are being properly identified
- Performed final audit by using dock audit checklist to verify conference to all specified requirements
- Prepared quality alerts, inspection plan, and updating work instruction as needed
- Maintained all records of the final product audit, including evidence
- Conducted torque tests, push tests, cut and etch test, and any other as specified on the inspection plan
- Checked the weld dimensions using the climax software and transferring the data to the quality engineer
- Prepared cut and etch report for the PPAP as per the customer weld specifications.
Education
PGDM in Quality Engineering Management -
Lambton College
Toronto, ON05.2017
Bachelors in Mechanical Engineering -
University of Kerala
India08.2013
Skills
- Continuous Improvement
- PPAP
- PFMEA
- 8D Problem Solving
- CARs
- Root Cause Analysis
- Control Plans
- HACCP
- Quality Function Deployment (QFD)
- ISO 9001
- FSSC 22000
- ISO TS 16949
- MS Office
- MS Excel
- Minitab
- Cyframe(ERP)
- Team management
- Communication abilities
- Cross-functional collaboration
- Blueprint Reading
- Product Development
- Injection Molding
- Extrusion and thermoforming
Certification
- Qualimpex - Internal auditor certification
- CMMXYZ- PCDMIS programming level 1 certification
- ENGEL - Injection Molding Level 7 certification
Timeline
Quality Engineer
E.Hofmann Plastics
04.2022 - Current
Quality Technician
The Hi-Tech Gears Canada
09.2020 - 04.2022
Jr. Quality Engineer
DBG CANADA LTD
07.2017 - 04.2020
PGDM in Quality Engineering Management -
Lambton College
Bachelors in Mechanical Engineering -
University of Kerala
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