Mukesh Morar
Brampton,ON
Summary
Quality Assurance Manager in Automotive field with a wide range of cross-functional experience in the automotive and precision machining industries. Able to work on own initiative and as part of a team. Proven leadership skills involving training, managing and motivating teams to achieve their objectives. First-class analytical, design and problem solving skills. Dedicated to maintaining high quality standards.
Overview
28
28
years of professional experience
Work History
Acting Quality Manager
Stackpole
- 6 months temporary position; responsible for staff of 18
- Arranged training for staff in QA program requirements and specific elements
- Monitored, analyzed and tracked both internal and external complaint investigations and implemented corrective / preventive action plans
- Implemented Quality Layered Process Audits (LPA) and surveillance activities
- Member of company quality audit team (QS-9000/TS-16949 internal quality auditor).
Sr. Quality Engineer
IAC Automotive
08.2014 - Current
- Drove standardization efforts across multiple production lines to ensure consistent product output meeting stringent specifications.
- Facilitated training sessions on various topics including statistical process control techniques, lean principles, or problem-solving methodologies for enhancing employee competencies within the organization.
- Developed comprehensive quality assurance plans, ensuring compliance with industry standards and regulations.
- Conducted regular audits of suppliers and vendors to maintain high-quality supply chain management.
- Served as liaison between engineering, manufacturing, and customers to address concerns regarding product quality or performance issues.
- Championed process improvements initiatives, leading to reduced cycle times and increased production yields.
- Improved product quality by implementing robust testing procedures and updating manufacturing processes.
- Created detailed reports analyzing trends in product performance, identifying areas for enhancement or improvement.
- Collaborated with cross-functional teams to optimize design, manufacturing, and validation processes.
- Streamlined production lines for increased efficiency, reducing defects and minimizing waste.
- Provided technical support in resolving complex quality issues by conducting thorough investigations and presenting data-driven recommendations.
- Managed risk assessments to identify potential hazards and implement corrective actions for continuous improvement.
- Performed quality inspections and drafted reports to detail non-conforming material issues.
- Led problem-solving activities to quickly identify and permanently resolve quality and productivity issues.
- Supported quality team members during corrective action updates.
- Contributed to root cause analysis to determine core reason for failures and errors.
- Partnered with senior management to analyze issues and find appropriate solutions.
- Escalated concerns about project and process quality, referring discovered issues to engineering manager for correction.
- Maintained compliance with industry standards and regulatory compliance during managed projects.
- Designed and implemented quality control processes to facilitate customer satisfaction.
- Assisted in developing cost-effective solutions to engineering problems.
Senior Quality Engineer
PowerCor Mfg (new plant)
07.2011 - 01.2013
Quality Manager
Camcor Manufacturing
07.2010 - 01.2011
Quality Manager
Linamar Gear
01.2008 - 06.2010
- Linamar Gear manufactures gears components for BIG -3 automotive industries
- Responsible for (Tier 1- FORD –Sharonville Ohio, GM - GMDAT/SGM China/Korea) & CHRYSLER – Kokomo, CATERPILAR- Oxford, and ZF Industries GA), Others are TBK & SES- Solar Sun Catcher –Arizona
- Developing prototype gears for Honeywell for aerospace
- Responsible for Metallurgical Lab staff of 11 – for HEAT TREAT process we have 17- Batch Carburizing Furnaces in-house supporting all in-house heat treat of gears and 10-other sister plants of Linamar corporation
- Responsible for maintaining ISO/TS-16949:2009, CQI-9 – Heat Treat quality system, managing staff of 30.
Quality Engineering Manager
Stackpole / AGD
01.1997 - 01.2007
- Stackpole designs & manufactures powder metal components and assemblies for several automotive customers
- Managed 6 people in Gear Lab and 8 Quality Inspectors Responsible for (Tier 1- GM-Windsor/Warren, GMDAT/SGM China/Korea) & (Tier 2-Magna Powertrain – Syracuse NY & ZF Industries GA), Customers for Sprocket and Synchronizer Gears product line
- Implemented single piecework flow and eliminated multiple handling by operators at different operation processes
- Responsible for quality system in developing Sprocket Gears for GMDAT & SGM China
- Actively supported the resolution of product, process, and quality issues in design and development phases
- Effectively worked with stakeholders including engineering, tooling, production, logistics and customers in resolving technical issues
- Generate internal & external quality concerns reports and quality alerts to production.
Quality Engineer
Stackpole
01.2001 - 01.2003
- Managed two quality technicians
- Developed, implemented and monitored continuous improvement of all plant manufacturing processes.
Quality Engineer Manager
Stackpole
01.1997 - 01.2001
- Managed a staff of 14 Met Lab & QA Inspectors, Receiving Incoming & Final Inspection
- High volume Oil Pump assembly for GM Cadillac responsible for Powdered Metal, Assembly and Classification of gears
- Remained involved in all quality activities including PPAP, APQP, FMEA, MSA (design and implementation of speciality gauges & fixtures with GR&R less than 10%) and production shop’s SPC
- Involved in customer liaison for quality issues with Tier 1-GM-Windsor GM-Warren, Daimler Chrysler Detroit & Saltillo-Mexico & Tier 2- Borg-Warner NY & NPG NY, ZF Industries GA, Responsible for implementation of training, coaching and mentoring company leadership and management on corrective action system & audit techniques
- Key contributor in implementing QS-9000; member of internal quality auditor team.
Education
No Degree - Higher National Certificate in Engineering
Manchester Openshaw Technical College
Manchester, England.07.1982
Skills
- TS16949, Core tools APQP, PPAP, FMEA, CP, MSA
- Quality requirements for ISO/TS 16949-2009 standards
- Experience with supplier quality, auditing and approval of PPAP
- Experience with Mechanical Engineering Practices & Processes & Machining & Fabrication (Welding)
- Continuous Improvement, KANBAN, KAIZAN, Lean Manufacturing, JIT, DOE
- Computer skills; Internet, Word, Excel, Auto cad, MPACT, Minitab, Aqua Pro, SQC-Pack
- FORD & Daimler Chrysler Portal, GM (SupplyPower) Online PRR process
- 5 WHY”,”8D”, “8 steps” (KT-Problem Solving) and development of Control Plan, SPC, PFD, FMEA, SWI, TPM, and Error Proofing POKEYOKE
- Design drafted specialty gauges & fixtures for new and existing programs
- Internal Auditing
- Quality Management Systems
- Compliance Monitoring
- Corrective Actions
- Quality processes
- Regulatory Compliance
- Document Management
- Problem-solving abilities
- Continuous Improvement
- Quality Training
- Quality Metrics
- Familiarity with quality standards
- Total Quality Management
- Product Inspection
- Statistical analysis skills
- Document Control
- First-Article Inspection
- Customer Satisfaction
- Failure mode and effects analysis
- Performance monitoring
- Analytical mindset
- Measurement System Analysis
- Gage R&R Studies
- Preventive Actions
- Issue Resolution
- External Auditing
- Control Plan Development
- Operation Monitoring
- Validation Techniques
- Documentation Control
- Excellent researching skills
- Operational Improvements
- Process Capability Analysis
- Design of experiments
- Test method validation
- Decision-Making
- Team Leadership
- Problem Resolution
- Process Improvement
- Teamwork and Collaboration
- Computer Skills
- Interpersonal Relations
- Employee Development
- Negotiation
- Work Planning and Prioritization
- Hiring and Training
- Project Planning
- Task Delegation
- Staff Training
- Technical Proficiency
- MS Office
- Documentation And Reporting
- Negotiation and Conflict Resolution
- Goal Setting
- Performance Evaluations
- Quality Planning
Languages
English
Full Professional
Gujarati
Native or Bilingual
Accomplishments
- Rapid growth of current business at Linamar Gear from sales of $24M in 2008/9 to current forecast of $80M by end of 2010.
- Successfully implemented and PPAP’d - completed Jan 2007. Volume of over $2.5M per year.
- Saved the company $25,000 a month by reducing high scrap and rework on Gemini Driven Sprocket Gears.
- Implemented and achieved monthly savings of $8,000 in rework costs.
- Solved quality assurance problems which resulted in production stoppage on – ongoing basis.
Cell
(647)-980-7985
Qualificationseducation
- Completed CQE -courses at Sheridan College, Brampton
- Certified – Kepner–Tregoe Program Leader- in Problem Solving & Decision-Making Program
- Computer Aided Engineering, Tameside College, Ashton-U-Lyne, England; 1991
- Higher National Diploma Mechanical Engineer Technologist, Openshaw College of Technology, Manchester, England; 1983
References
Available upon request.
Training
- SAE AS9100 Rev B Internal Auditor – Certificate by BSI - 2009
- Lead Auditors Training – ISO 9001:2008 & TS16949:2009 –Certificate by BSI -2010
- Design of Experiments (University of Waterloo)
- Health & The Law Workshop for Industrial Accident Prevention Association (IAPA)
- Lean Manufacturing
- Leadership & Management Skills Development Workshop + 5S Workplace Organization
- Statistical Process Control (Avenier Training Services Inc)
- Kepner–Tregoe - Problem Solving & Decision-Making Program
- TOPS II Training in Problem Solving, WHMIS
- GD&T & Blue Print Reading (Avenier Training Services Inc)
- Advance & Basics of Powder Metal Compacting (Cincinnati Incorporated)
- Spline & Gear Advance Training by FRENCO, CMM Programming & Report Reading
- FMEA (Process & PPAP and APQP to AIAG Standard)
Timeline
Sr. Quality Engineer
IAC Automotive
08.2014 - Current
Senior Quality Engineer
PowerCor Mfg (new plant)
07.2011 - 01.2013
Quality Manager
Camcor Manufacturing
07.2010 - 01.2011
Quality Manager
Linamar Gear
01.2008 - 06.2010
Quality Engineer
Stackpole
01.2001 - 01.2003
Quality Engineering Manager
Stackpole / AGD
01.1997 - 01.2007
Quality Engineer Manager
Stackpole
01.1997 - 01.2001
Acting Quality Manager
Stackpole
No Degree - Higher National Certificate in Engineering
Manchester Openshaw Technical College
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