Kiran Sonawane
Automotive Quality Control
Brantford,ON
Summary
Highly motivated Quality Assurance Technician with 29+ years of experience in the automotive and gearbox manufacturing industry. Proven expertise in quality inspection, process improvement, and root cause analysis. Proficient in ISO 9000/9001 and IATF 16949 standards. Strong skills in using precision measuring equipment and Microsoft Office Suite. Dedicated to ensuring product quality and continuous improvement.
Experienced with operating and maintaining production equipment efficiently. Utilizes problem-solving skills to minimize downtime and improve workflow. Knowledge of safety protocols and quality control standards to ensure consistent product quality.
Overview
29
29
years of professional experience
1
1
Certification
Work History
Quality Assurance Technician
Deco Automotive - The Division of Cosma International of Magna international
09.2018 - 11.2024
- Company Overview: A leading manufacturer of automotive parts supplier
- Effectively conducted incoming material inspections, including F/O and L/O checks using check fixtures, minimizing the risk of defective parts entering the production process and preventing downstream quality issues
- Successfully utilized a variety of measuring instruments, including calipers, micrometers, verniers and height gauges, and applied metrology concepts such as uncertainty analysis and calibration procedures to accurately verified part dimensions and ensured conformance to engineering drawings and specifications
- Knowledge of standard sampling plans, including variable and attribute sampling methods as defined by ISO standards
- Provided key insights into IATF 16949 audit preparation at Deco Automotive, leading to successful certification with zero major nonconformities, also conducted regular product and process audits to ensure compliance with quality standards
- Performed Poke Yoke audits and developed boundary samples for team members
- Reduced production downtime by 20% by implementing a rapid root cause analysis process utilizing fishbone diagrams and fast response boards
- Furthermore, it involved applying Lean Manufacturing principles and Six Sigma methodologies to identify and resolve quality issues effectively
- Initiated supplier quality improvement program that bolstered component quality by 12%
- Leveraged quality improvement tools such as 8D, 5 Why analysis, and team-based problem-solving techniques to effectively address quality issues and drive continuous improvement
- Implemented containments and provided clean point and trained personnel for third party inspections
- Successfully utilized ERP system to manage all aspects of incoming material inspections, including data entry, quality checks, and inventory updates, contributing to improved data accuracy and informed decision-making
- Effectively collaborated with cross-functional teams in a fast-paced environment, demonstrating strong communication, interpersonal, and organizational skills while effectively multitasking to achieve shared objectives
- Issued Quality Alerts and QPFs to address nonconformances, collaborating with suppliers and initiating chargebacks
- Compiled and documented evidence and technical details pertaining to each nonconformance, effectively communicating findings to relevant stakeholders such as SQE, material planners, and operations
- Compiled, created, and communicated nonconformance data to support root cause analysis, corrective and preventive action (CAPA) implementation, and continuous improvement initiatives
- Eager to learn and develop mechanical skills, particularly in hands-on repair and maintenance of mechanical and/or electronic systems
- A leading manufacturer of automotive parts supplier
E-coat Technician
Deco Automotive
12.2012 - 09.2018
- Led APQP activities for E-coat line, including sample preparation, testing, and PPAP submissions for Design Validation, Product Validation, Tool Trial, and Production builds
- Successfully launched mass production of E-coated parts
- Operated and maintained the E-coat line, achieved consistent quality and efficiency by 18% by following schedule of regular maintenance of phosphate tank and RO Unit
- Overhauled wastewater treatment plant operations, ensuring environmental compliance and maintained strict guidelines
- Performed daily chemical analysis and conducted rigorous testing (adhesion, cure, thickness) to maintain optimal coating performance
- Reduced rework by nearly 38% through regular tank maintenance, proper chemical additions, and effective resolution of paint defects
Weld Destruct Technician
Deco Automotive
08.2005 - 12.2012
- Utilized Clemex Vision Lite for 100% inspection and archival of weld measurements (safety and regular) ensuring precise data collection and adherence to quality standards
- Improved production efficiency by 25% by conducting thorough spot weld inspections using airguns and vernier calipers and implementing timely corrective actions such as replacing worn tips
- Collaborated with engineering to improve weld processes and developed master samples for production
- Maintained lab documentation, equipment calibration, and 5S practices followed
- Supported containment efforts and assisted with weld fixes on production lines by validating the weld data as per specification
- Operated plasma cutting machine and effectively communicated with cross-functional teams for weld fixes
Junior Engineer (Heat Treatment, Foundry and Welding)
Premium Energy Transmission Ltd.
08.1996 - 04.2005
- Company Overview: Premium provides high quality, precision engineered power transmission solutions and products to the global engineering industry
- Managed a team of 25, including heat treat operators, foundry operators, and welders, ensuring safety and operational efficiency
- Supervised the production of high-quality phosphor bronze castings and minimized defects in castings
- Maintained ISO 9001 compliance and assisted for audit by maintaining the documentations
- Managed processes and operated furnaces of gas carburizing, nitriding, annealing, normalizing, tempering and quenching to achieve desired properties
- Archived micro-structural data for quality assurance, process improvement and documentations
- Utilized ultrasonic and dye penetrant testing to ensure component integrity of gear, pinions and worms
- Performed Rockwell and Brinell hardness testing to verify material properties
- Premium provides high quality, precision engineered power transmission solutions and products to the global engineering industry
Junior Engineer (Electroplating)
Kirloskar Oil Engines Ltd.
08.1995 - 08.1996
- Company Overview: KOEL - Kirloskar Oil Engines Ltd is the largest diesel engine manufacturer in India
- Led a team of 6 in a Bimetal/Tri-Metal electroplatining plant
- Ensured high-quality output by conducting thorough inspections and measurements using precision instruments
- Maintained the chemical lab and trained production personnel on quality procedures
- Demonstrated adaptability and problem-solving skills in a fast-paced environment
- Experienced in quality control, inspection, and process improvement across various manufacturing settings
- Successfully collaborated with cross-functional teams in a fast-paced environment, demonstrating strong communication, interpersonal, and organizational skills while effectively multitasking to achieve shared objectives
- KOEL - Kirloskar Oil Engines Ltd is the largest diesel engine manufacturer in India
Education
Engineering Diploma - Metallurgy
Government Polytechnic Pune
University Rd, Ganeshkhind, Pune, India 05.1992 - 05.1995
High School Diploma -
Acharya Shri D. B. Dadawala Jr. College
1433, Ganesh Rd, Kasba Peth, Pune, MH, India 03.1990 - 03.1992
Courses - Engineering Drawing, Foundry Technology, Moulding Technology, Mechanical Maintenance
Government Technical High School
Ghole Rd, Sumukh Society, Shivajinagar, Pune, Maha03.1992
Skills
- Testing procedures
- Attention to detail
- SOP enforcement
- Project coordination
- Equipment inspection
- Multitasking and organization
- Quality assurance understanding
- Physical stamina and strength
- Lab equipment maintenance
- Continuous improvement mindset
- Written/Verbal communication
Certification
- Lean Six Sigma Yellow Belt Certification - Comprehensive training and certification completed on LinkedIn on Lean Six Sigma Methodologies (DMAIC)
- Quality Management for Operational Excellence - Gained practical skills in applying quality tools and techniques, including process mapping, data analysis, and problem-solving methodologies
- PPG Knowledge College - Completed a 4-day PPG Paint Technologies training course, specializing in Electrocoating Processes at the Advanced Technology Training Center in Cleveland, Ohio. Gained in-depth knowledge of electrocoating principles, best practices, and troubleshooting techniques
- Magna Certifications - Top Focus Suppliers, Warranty Management, Layered Process Audit, Quality Gates, Global leadership competencies, Error Proofing and Detection Device Verification, Continuous Risk Reduction, Customer Interface Characteristics, Quality management, Risk Mitigation, Data Security, Diversity, Compliance, Red Flag, Fast Response, Incoming Inspection and Material Receiving and Change Management.
Languages
English
Full Professional
Hindi
Full Professional
French
Elementary
Marathi
Bilingual or Proficient (C2)
1st Prize for the production of S. G. Iron
Received first prize for the project in the final year of Diploma in Metallurgy; " Production of S.G. Iron".
Timeline
Quality Assurance Technician
Deco Automotive - The Division of Cosma International of Magna international
09.2018 - 11.2024
E-coat Technician
Deco Automotive
12.2012 - 09.2018
Weld Destruct Technician
Deco Automotive
08.2005 - 12.2012
Junior Engineer (Heat Treatment, Foundry and Welding)
Premium Energy Transmission Ltd.
08.1996 - 04.2005
Junior Engineer (Electroplating)
Kirloskar Oil Engines Ltd.
08.1995 - 08.1996
Engineering Diploma - Metallurgy
Government Polytechnic Pune
05.1992 - 05.1995
High School Diploma -
Acharya Shri D. B. Dadawala Jr. College
03.1990 - 03.1992
- Lean Six Sigma Yellow Belt Certification - Comprehensive training and certification completed on LinkedIn on Lean Six Sigma Methodologies (DMAIC)
- Quality Management for Operational Excellence - Gained practical skills in applying quality tools and techniques, including process mapping, data analysis, and problem-solving methodologies
- PPG Knowledge College - Completed a 4-day PPG Paint Technologies training course, specializing in Electrocoating Processes at the Advanced Technology Training Center in Cleveland, Ohio. Gained in-depth knowledge of electrocoating principles, best practices, and troubleshooting techniques
- Magna Certifications - Top Focus Suppliers, Warranty Management, Layered Process Audit, Quality Gates, Global leadership competencies, Error Proofing and Detection Device Verification, Continuous Risk Reduction, Customer Interface Characteristics, Quality management, Risk Mitigation, Data Security, Diversity, Compliance, Red Flag, Fast Response, Incoming Inspection and Material Receiving and Change Management.
Courses - Engineering Drawing, Foundry Technology, Moulding Technology, Mechanical Maintenance
Government Technical High School
Similar Profiles
BHUPENDRAKUMAR PANCHALBHUPENDRAKUMAR PANCHAL
Material Handler or Forklift Driver at Deco Automotive A Div. Of Cosma InternationalMaterial Handler or Forklift Driver at Deco Automotive A Div. Of Cosma International
PAUL JOHN TAYOMORAPAUL JOHN TAYOMORA
Machine Operator at Tool, Cosma. International Group of Magna International IncMachine Operator at Tool, Cosma. International Group of Magna International Inc
Timberly ThornbergTimberly Thornberg
Quality Assurance/Customer Liaison Officer at Magna International/Cosma/LMVQuality Assurance/Customer Liaison Officer at Magna International/Cosma/LMV