Kiran Sonawane
Automotive Manufacturing Quality Technician
Brantford,Canada
Summary
Professional with significant experience in quality assurance, prepared for ensuring top-notch product standards. Strong focus on team collaboration and achieving impactful results. Dependable and flexible, adept at identifying defects, implementing corrective actions, and maintaining compliance with industry standards. Known for precision in executing test plans, excellent problem-solving skills, and strong communication with cross-functional teams.
Overview
30
30
years of professional experience
1
1
Certification
Work History
Quality Assurance Technician
MAGNA INTERNATIONAL, INC.
01.2005 - Current
- Company Overview: Magna operates in 28 countries with more than 340 manufacturing facilities and 89 product development, engineering, and sales centers
- Conducted comprehensive inspections and tests on incoming materials, in-process components, and finished products to ensure compliance with quality standards
- Enhanced overall product quality by establishing robust quality checks and monitoring processes
- Identified and resolved quality issues and non-conformances through root cause analysis and corrective actions
- Implemented containments and provided clean point
- Created work instructions for containment
- Trained third party inspectors, supervisor, operators and company team leaders on the containments
- Performed Poke Yoke audits and run the red rabbits to challenge the poke yokes and the operators
- Developed boundary samples
- Trained end of line inspectors on the boundary Samples
- Collected and organized third-party data into Excel spreadsheets, conducted detailed analyses, and reported findings to the Quality Supervisor and the Manager
- Provided actionable insights to support decision-making and continuous improvement initiatives
- Maintained accurate records of inspections, tests, and quality audits
- Trained and mentored production staff on quality standards and procedures
- Performed dimensional checks, surface quality, material properties, dimensional accuracy, visual inspection of hydroforming and stamping components
- Identified common defects in aluminum components, such as porosity, cracking, warping during inspections
- Participated in or led investigations to determine the root cause of defects, by using the tools like 3 legged 5 Whys, fishbone diagram etc
- Implemented corrective and preventive actions
- Developed and issued Quality Alerts to promptly address quality issues, ensuring that all relevant personnel were informed, and corrective actions were taken to prevent recurrence
- Conducted comprehensive training sessions for operators, team leaders, and production supervisors on quality standards, procedures, and the importance of adhering to Quality Alerts
- Worked closely with cross-functional teams, including production, engineering, and quality assurance, to address quality issues and implement effective solutions
- Effectively issued QPFs to address nonconforming materials, ensuring timely communication with suppliers to resolve quality issues and prevent recurrence
- Collaborated with suppliers to implement corrective actions and improve material quality
- Updated QPF and communicated with SQE to charge back suppliers
- Magna operates in 28 countries with more than 340 manufacturing facilities and 89 product development, engineering, and sales centers
- Conducted root cause analyses for identified defects, implementing preventive measures to minimize recurrence rates.
- Performed thorough inspections of incoming materials and outgoing products.
- Contributed to continuous improvement initiatives by actively participating in regular team meetings and sharing insights about potential areas of improvement.
- Inspected finished products for overall quality and adherence to [Type] specifications.
Quality Control Technician / E-coat Technician
DECO AUTOMOTIVE
01.2012 - 01.2018
- Worked with Quality Engineer on APQP Phases for E-coat line samples building for Design Validation build, Product validation build, Tool Trial build, Production parts build, and the Mass Production builds
- Prepared samples for the Production Part Approval Process (PPAP) and conducted comprehensive testing of e-coated samples to ensure compliance with quality standards and customer specifications
- Coordinated with cross-functional teams to address any issues and validate the production readiness of components
- Operated and maintained the e-coat line, which was crucial for producing high-quality parts
- Monitored process parameters, carried out regular maintenance, and resolved any issues that arose to ensure consistent quality and efficiency in production
- Oversaw the operation and performance of the wastewater treatment plant, ensuring compliance with environmental regulations and quality standards
- Monitored key process parameters, conducted regular inspections, and addressed any issues to maintain optimal plant performance and discharge quality
- Conducted daily and hourly checks of chemical samples for the e-coat manufacturing system, including wet chemistry analysis, titrations, solids measurement, and coating weights
- Ensured that chemical concentrations and application properties met quality standards for optimal coating performance
- Specialized in testing and evaluating e-coat samples, including Adhesion Test, Cure Tests, and Thickness Measurement
- Conducted thorough inspections of coated parts to ensure they met quality standards, checking for defects, coating consistency, and adherence to specifications
- Maintained accurate and organized records by logging all pertinent data and production information
- Ensured that documentation was up-to-date, accessible, and compliant with quality standards for future reference and audits
- Correctly categorized and identified paint defects, including issues such as runs, sags, or discoloration
- Implemented corrective actions to resolve defects and improve coating quality, ensuring that finished products met quality standards
Quality Control Technician / Weld Destruct Technician
DECO AUTOMOTIVE
01.2005 - 01.2012
- Utilized Clemex Vision Lite image analysis software for precise weld measurement, ensuring adherence to quality standards and provided archival records of weld destruct data for customers using Clemex Vision Lite software, ensuring accurate and reliable documentation
- Checked spot welds for nugget size by using airguns to open the welds, measuring with Vernier caliper, recording the diameter of the nuggets and ensuring that welds are in specifications and are of good quality
- Collaborated with engineering teams to provide detailed analysis and recommendations for process improvements
- Developed and prepared master samples to guide production teams in maintaining accurate weld locations, identification numbers, and standard weld lengths
- Collaborated with production and quality teams to ensure welds met required specifications and standards
- Maintained comprehensive lab documentation, ensuring all records were accurate, up-to-date, and compliant with quality standards
- Managed and tracked the expiry dates of equipment stickers, ensuring all lab equipment was calibrated and certified within required timelines
- Supported containment efforts by identifying and isolating defective welds and collaborating with production teams to implement corrective actions
- Assisted with weld fixes on production lines, troubleshooting and resolving weld-related issues to ensure production quality
- Managed the handling of bio-hazardous and radioactive materials within the lab, ensuring compliance with laboratory safety standards and regulations
- Oversaw laboratory maintenance activities, including the preparation of solutions and media, and managed the stock and ordering of supplies to ensure smooth lab operations
- Maintained all paperwork and documentation required for TS 16949 and QS 14000 standards, ensuring adherence to industry quality management systems
- Applied 5S techniques within the lab to organize workspaces, streamline processes, and reduce waste, contributing to enhanced efficiency and productivity
- Operated plasma cutting machine and regularly coordinated and communicated with weld engineers, weld technicians, and management, providing updates on weld discrepancies and ensuring timely resolution
Junior Engineer
PREMIUM ENERGY TRANSMISSION LTD.
01.1996 - 01.2005
- Directed a team of 25, including 9 heat treatment operators, 12 phosphor bronze foundry operators, and 4 welders
- Delivered training on safety protocols and equipment operation, fostering a secure and efficient work environment
- Supervised the production of phosphor bronze centrifugal castings, ensuring alignment with shop floor requirements and high-quality standards
- Maintained detailed documentation for ISO 9000/9001 standards, ensuring compliance and supporting quality management systems
- Designed and optimized heat-treating fixtures for compatibility with furnace operations, enhancing process efficiency and product quality
- Managed and operated gas carburizing, gas nitriding, annealing, and tempering processes, ensuring precise control and high-quality outcomes
- Archived micro-structural data for steel, gas carburized, and gas nitride samples, providing essential records for quality assurance and detailed analysis to support process improvements and compliance
- Utilized ultrasonic testing to detect internal and surface flaws in components, ensuring structural integrity and performance
- Conducted dye penetrant testing to identify surface-breaking defects and ensure quality and reliability
- Operated Rockwell and Brinell hardness testing machines to measure material hardness, verifying proper heat treatment and material properties for components without compromising the integrity of the parts
Junior Engineer
KIRLOSKAR OIL ENGINES LTD.
01.1995 - 01.1996
- Directed the activities of a team of 6 workers in the Bimetal (Pb-Sn) and Tri-Metal (Pb-Sn-Ni) electroplating plant for engine bearings, ensuring efficient operations and high-quality output
- Utilized micrometers, verniers, calipers, and dial indicators to measure electroplating and material thickness, ensuring compliance with specifications
- Checked first-off and last-off electroplated components to verify that all parts met quality standards
- Conducted frequent visual inspections for plating thickness, uniformity, dust deposition, and overall quality to minimize rework
- Maintained the chemical lab for bath composition, ensuring accurate and consistent plating solutions
- Demonstrated a sense of urgency and adaptability in a fast-paced environment, achieving timely results while maintaining quality
- Trained production personnel on quality and inspection procedures, enhancing their understanding and adherence to quality standards
Education
Training, Certification, and Licenses - Automotive Industry
MAGNA INTERNATIONAL INC.
11.2024
Diploma - Metallurgy
GOVERNMENT POLYTECHNIC PUNE
05.1995
High School Diploma - Higher Secondary Certification Examination
ACHARYA SHRI D. B. DADAWAL JUNIOR COLLEGE
03.1992
Courses - Engineering Drawing, Foundry Technology, Moulding Technology, Mechanical Maintenance
VOCATIONAL EDUCATION AND TRAINING
01.1992
Skills
- Proficient in Word, Excel, PowerPoint
- Metallurgical Software: Proficient in Clemex Vision Lite for metallurgical analysis and image processing
- Documentation skills
- Auditing
- Lab equipment maintenance
- Calibration standards
References
Available upon request.
Languages
English
Full Professional
Hindi
Full Professional
Marathi
Native or Bilingual
Certification
- Lean Six Sigma Yellow Belt Certification – LinkedIn.
Timeline
Quality Control Technician / E-coat Technician
DECO AUTOMOTIVE
01.2012 - 01.2018
Quality Assurance Technician
MAGNA INTERNATIONAL, INC.
01.2005 - Current
Quality Control Technician / Weld Destruct Technician
DECO AUTOMOTIVE
01.2005 - 01.2012
Junior Engineer
PREMIUM ENERGY TRANSMISSION LTD.
01.1996 - 01.2005
Junior Engineer
KIRLOSKAR OIL ENGINES LTD.
01.1995 - 01.1996
Diploma - Metallurgy
GOVERNMENT POLYTECHNIC PUNE
High School Diploma - Higher Secondary Certification Examination
ACHARYA SHRI D. B. DADAWAL JUNIOR COLLEGE
Courses - Engineering Drawing, Foundry Technology, Moulding Technology, Mechanical Maintenance
VOCATIONAL EDUCATION AND TRAINING
Training, Certification, and Licenses - Automotive Industry
MAGNA INTERNATIONAL INC.
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