Summary
Overview
Work History
Education
Skills
Certification
Timeline
Generic

Pavan Lucca

Farmington Hills,MI

Summary

Experienced manufacturing & supply chain with a demonstrated history of 8+ years of collaboration with OEM’s like Ford, General Motors and Stellantis and as well as Tier 1 / Tier 2 suppliers as well as 3PL. Skilled and experience in APQP/PPAP, Root Cause Analysis, Corrective / Preventive actions (CAPA), Continuous Improvement, Lean Manufacturing, JIT, 5S, Kaizen and Internal Auditing. Results-driven Senior Quality Engineer recognized for productivity and efficiency in task completion. Possess specialized skills in statistical process control, risk management, and continuous improvement methodologies. Excel in problem-solving, teamwork, and communication; ready to leverage these soft skills to achieve quality assurance objectives and enhance operational excellence.

Overview

10
10
years of professional experience
1
1
Certification

Work History

Sr. Quality Engineer

DP world
Warren, Michigan
09.2017 - Current
  • Gather data from customer and internal sources as an input for problem solving and communicate to appropriate personnel with root cause findings
  • Developing and designing irreversible corrective actions for known problems
  • Using problem-solving techniques to reduce process variation
  • Responsible and controlling PCR process within the site changes by involving all management team
  • Actively coach the organization concerning quality with tools and reports
  • Maintaining a lean culture within the organization using a hands-on approach
  • Worked on preparing documentation for MLM JIT operations audit, 3PL audit as per customer standards
  • Quality Management Systems – Supports organization in maintaining, managing and conducting in internal audits, update and maintain customer scorecards and other QMS improvement activities, as assigned
  • Generate and communicate results to management team by using reports like (PPM’s LPA’s, KPI’s)
  • Excellent in using company data base tool for controlling plant wise documentation within the company standards
  • Creating and scheduling Layer Process Audit which is performed by various levels of management between the plant wise
  • Assisted with internal audits conducted by external agencies or third parties.
  • Working closely with third party group by using the QMR process and maintaining relationships with supplier to deal with suspect material
  • Conducted root cause analysis on production issues related to non-conforming products.
  • Evaluated customer feedback and complaints to identify areas of improvement in product quality.
  • Performed auditing activities to verify adherence to established quality standards.
  • Provided training and guidance to staff on quality systems, tools, methods and techniques.
  • Collaborated with other departments such as engineering and production for process improvements.
  • Investigated customer returns and complaints utilizing problem solving techniques such as 8D or 5 Why Analysis.
  • Ensured proper documentation of corrective actions taken following internal audits or customer complaints.
  • Developed Key Performance Indicators for measuring overall performance of the Quality Assurance Department.

Quality Engineer

Zimmer Biomet
Warsaw, Indiana
04.2017 - 09.2017
  • Company Overview: Manufacturer of medical devices and related products
  • Formulating procedures, specifications, and standards for Zimmer products and processes
  • Developed and implemented corrective/preventative action plans
  • Collects and analyzes data for gauge and product evaluation
  • Identifies critical personnel, gauges, procedures, and materials needed for the completion of new products
  • Ensures that suppliers have necessary information and facilities to deliver quality products to Zimmer
  • Basic knowledge of blueprint reading and GD&T basic understanding of QSR/ISO regulations, design assurance, FMEA, and product testing methods, and can use optical comparators and CM
  • Manufacturer of medical devices and related products

Quality Engineer

Sakthi Automotive Group
Detroit
04.2015 - 03.2017
  • Company Overview: Manufacturer of Knuckles, axles and Brackets for General Motors (GM) and Ford Motor company
  • Generate and managed APQP & PPAP (Control Plans, PFMEA’s, MSA, PSW, QC documentations such as quality manuals, quality procedures, quality standards, QA policies) etc
  • For all production and prototype programs
  • Prepared PPAP documentation, facilitating run at rate activities and conduct capability analysis studies
  • Resolved customer complaints (PRRs), took preventive measures to avert future complaints, and clearly documented and all feedback
  • Conducting the Material Review Board (MRBs) of formal reviews for defect control changes, oversee the compliance with specified requirements
  • Responsible for conducting and maintaining Fast Response Board (FRB) meetings to discuss daily issues on the floor and ensure the system implemented is being followed
  • Supported upkeep of the calibration system
  • Maintained records, ensured gages and equipment are calibrated within required time
  • Participated in various Continuous Improvement activities designed to reduce the cost of poor quality
  • Conducting biweekly scrap review meeting
  • Creating Quality Trends monthly to review the performance of each line in the plant
  • Manufacturer of Knuckles, axles and Brackets for General Motors (GM) and Ford Motor company
  • Implemented ICEBERG software for both In-Process inspections and GP-12 inspections resulting in reduction of paperwork
  • Trained and supervised a team of 30 Quality Inspectors on Continuous Improvement and quality measuring techniques
  • Able to manage multiple programs excellent leadership and communication skills

Education

Master of Science - Automotive Engineering

Lawrence Technological University (LTU)
Detroit, MI
05.2016

Bachelor of Science - Mechanical Engineering

Jawaharlal Nehru Technological University
India
05.2013

Skills

  • 5WHY
  • Problem solving
  • Lean
  • Value Stream Mapping
  • 8D
  • Fishbone
  • Pareto charts
  • PFMEA
  • Control Plan
  • APQP
  • Time Study
  • ISO 9001:2015
  • TS 16949
  • GD&T
  • SPC
  • Gage R&R
  • MSA
  • Microsoft Office Suite
  • Visio
  • Nextgen
  • Bluezone

Certification

  • Lean six sigma green belt certified
  • Certified as a lead auditor for ISO 9001 2015 for site level

Timeline

Sr. Quality Engineer

DP world
09.2017 - Current

Quality Engineer

Zimmer Biomet
04.2017 - 09.2017

Quality Engineer

Sakthi Automotive Group
04.2015 - 03.2017

Master of Science - Automotive Engineering

Lawrence Technological University (LTU)

Bachelor of Science - Mechanical Engineering

Jawaharlal Nehru Technological University

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Pavan Lucca