Shanmuga M

• Review and approve all engineering drawings in line with customer PO requirements, standards, datasheets, and certifications prior to production release, including mechanical design aspects.
• Provide technical solutions and support to the Sales/Proposal team during the bidding stage of projects.
• Develop supplier quality programs, including training initiatives and supplier audits.
• Create, review, and update Quality Manual, procedures, work instructions (WI), and SOPs to drive process optimization.
• Strengthen the QA team by enhancing first article inspection, process control activities (IQC, IPQC, and OQA), ensuring effective training, monitoring, and execution of daily tasks.
• Drive supplier performance improvements in quality and on-time delivery.
• Lead and conduct annual internal audits, ensuring closure of nonconformities and follow-up action plans.
• Coordinate with external and third-party auditors, manage audits, and track implementation of corrective actions.
• Maintain and drive continual improvement of QMS, EMS, and OH&S systems, covering audits, documentation, and compliance.
• Prepare, review, and update risk assessments, including risk evaluation and mitigation measures.
• Management Representative for Quality Management System, ISO9001,ISO14001 & ISO45001.
• Conduct systematic and periodic Quality Management (QM) and EHS audits and assessments to ensure compliance with global policies, guidelines, and standards such as ISO 9001:2015 and ISO 45001:2018 within the solutions and services business.
• Conduct incident investigations and root cause analyses for workplace injuries, prepare lessons learned reports, and provide timely incident reporting to management.
• Lead Root Cause Analysis (RCA) to identify process gaps, prevent non-conformances and associated costs (NCC), and drive continuous improvement initiatives using the PDCA methodology across the organization

Strategic and results-driven leader with proven expertise in operations management, quality assurance, and process improvement. Skilled at aligning customer needs with organizational goals to drive revenue growth, operational excellence, and sustainable quality culture across all functions, including sales, engineering, purchasing, inventory, QA/QC, and production.

Key Responsibilities & Achievements

Directed end-to-end operations, ensuring seamless integration of sales, engineering, procurement, production, warehousing, and quality functions.

Developed and executed effective quality control processes in line with ISO 9001:2015, ensuring compliance with industry standards and regulatory requirements.

Partnered with sales and proposal teams to review project specifications, manage clarifications, and lead KOMs (Kick-off Meetings) to align all stakeholders on project goals and delivery schedules.

Spearheaded procurement strategies by negotiating with at least three vendors per component to secure the best price, lead time, and quality, while establishing long-term blanket orders and global supplier agreements.

Led cross-functional teams in engineering and procurement to accelerate material approval, procure standard items in advance, and reduce lead times through cost-effective logistics planning.

Managed international collaborations with factories in Germany, Italy, and India for technical clarification and customer complaint handling, driving continuous improvement initiatives.

Championed Lean practices to optimize workflows, eliminate inefficiencies, and deliver annual cost savings through process improvement and risk management initiatives.

Conducted yearly management reviews, 8D reporting, and CAR submissions to clients, while mentoring teams on corrective actions and root cause analysis.

Completed ATEX / IECEx training in Germany and Italy, gaining strong expertise in hazardous products compliance and regulatory standards.

• Mechanical Troubleshooting & Welding Verification
  Diagnose and troubleshoot mechanical issues on Heat Exchangers and Power Generators.
  Review and confirm welding parameters against design specifications.
  Verify welding strength and mechanical rigidity of fabrication structures, piping systems, and exchanger tanks.
• In-Process Inspection & Quality Control.
  Perform in-process inspections across all stages: turret punching, bending, welding, assembly, and painting.
  Inspect painting layers and measure thickness to ensure compliance with customer requirements.
  Conduct cross-cut adhesion tests to verify coating durability.
• Process Improvement & Documentation
  Maintain and continuously improve manufacturing processes, work instructions, inspection plans, and quality procedures.
  Support production teams with corrective feedback to enhance process efficiency and product reliability.
• Quality Claims & CAPA Management
  Manage and investigate all quality claims.
  Prepare and implement Corrective and Preventive Actions (CAPA) for reported issues.
  Monitor effectiveness of CAPA and ensure timely closure of claims.
• Audits & Compliance
  Conduct yearly internal audits and supplier audits as per ISO/quality system requirements.
  Host and facilitate management review meetings to discuss quality performance and improvement actions.
  Engage with external auditors, prepare audit documentation, and attend external certification audits.

Supplier & Subcontractor Management
Assess, review, approve, and maintain the approved list of suppliers and subcontractors in line with company guidelines and procedures.
Monitor supplier performance and compliance with quality standards.

Inspection & Quality Verification
Perform incoming inspection of machining precision parts using CMM machines, profile projectors, and other metrology equipment.
Conduct First Article Inspections (FAI) from raw materials to final finished parts, including 100% inspection and reporting.
Verify welding quality standards and confirm welded parts meet drawing specifications and welding symbols.

Project Quality Assurance
Attend and represent the company in quality meetings with clients to define and validate project requirements.
Prepare and provide project-specific documentation such as FMEA, APQP, Control Plans, and Project Schedules.

Problem Solving & Corrective Actions
Prepare 8D reports for rejected parts and follow up on corrective actions to ensure closure.
Lead root cause analysis and preventive actions for recurring issues.

Team Leadership & Development
Supervise, coach, and develop a team of Quality Technicians and Inspectors to build skills and achieve quality objectives.

Auditing & Compliance
Conduct quarterly internal audits, with a focus on stores and semi-conductor-related products.
Perform internal and external audits, plan corrective actions, and ensure timely closure of nonconformities.
Act as liaison with external auditors for certifications and compliance checks.

Documentation & Process Control
Work as Document Controller, ensuring all records, reports, and documents are properly prepared, maintained, and controlled.
Develop, maintain, and improve processes, work instructions (WI), inspection plans, and SOPs

Quality Control & Reporting
Perform QC inspections and prepare detailed inspection reports.
Carry out final 100% inspections before delivery to ensure compliance with specifications.

Welding & GD&T Verification
Inspect welded assemblies in accordance with drawing requirements and welding symbols.
Verify dimensional accuracy using Geometric Dimensioning & Tolerancing (GD&T) standards.

Product & Process Development
Support new product development activities with a focus on quality validation.
Conduct problem-solving and root cause analysis to address quality issues.
Perform tooling and welding inspections as part of the Production Part Approval Process (PPAP).

Supplier Quality Management
Engage in supplier development activities, including on-site inspections at supplier premises.
Verify supplier components and processes to ensure conformity with quality requirements.

Precision Measurement & Semiconductor Products
Inspect semiconductor products and precision components using CMM machines and other advanced metrology tools.
Document inspection results and ensure traceability for all quality checks.

• New product development activity, Problem solving, overall Inspection
• Tooling and Welding Inspection & Production Part Approval Process (PPAP).
• Supplier Development Activities