1. B. K. SRINIVASA RAO.
Mobile: +9694092039; Phone: 01493-510379; Email: bksrao@yahoo.com
Seeking assignments in Manufacturing Enhancement / Quality Assurance with a growth oriented
organisation.
SYNOPSIS
 A competent professional with nearly 26 years of extensive experience in Manufacturing Operations.&
Quality Management Systems
 Currently associated with Alicon cast alloys limited as a HOD QA At PUNE, Mahrastra
 Demonstrated abilities in working on initiatives, thereby bringing down equipment breakdown & achieving
annual costs savings. Improved productivity by technology management.
 Adroit in identifying areas of strength & weakness and implementing company polic ies, standards, changes
that optimize productivity & control costs through most effective use of manpower & available resources.
 Significant expertise in carrying out Trend Analysis, Process Capability, Qualitative Assessment, Reliability and
Validity tests. Well versed with TPM, TQM.
 Internal Auditor Certified for TS-16949, ISO-14001 & OHSAS.
 Lead auditor course attend for ISO-19198
 Adept in developing quality systems, conducting audits and maintaining relevant documents for the same.
 Excellent interpersonal & Negotiation skills with strong analytical, problem solving & organizational abilities.
 Excellent experience to deal the international customers like Navistar,piaggio, VMM,Eaton , Articcat,Hardely
Davidson,Volvo,Borgwarner, Mercury. Renault Nissan.
Career Highlights
 Reduced the COPQ (Cost of Poor Quality) to 40% by implementing a CFT work culture.
 Established Cylinder Block, Cylinder Head &Crank shaft & camshaft cell system in Hindustan motors.
 Established cylinder block process at tech tool(Chandigarh) during supplier development.
 DCM cylinder Blocks rejections bring down under 0.3% by continuous location analysis and feedback.
 Established Map ale tooling cylinder block crank bore & cylinder bores.
 Set up wise CNC programmes developed on Cincinnati milling M/c.for cylinder block.
 CNC camshaft programme developed on Fortuna cam grinding.
 Cycle time study conducted accordingly increase the production volumes
 Whittle role played during diesel cylinder block development.
 Active participation in cross functional teams.
 Implemented quality systems in new machining division of continental engines limited.
 Set up the training concepts in Continental.
 Effectively implemented Q.C circles in Q. H. Tabors Limited.
 Effectively developed mass production items like handle, chain case,saree guard,
 Effectively developed home furnishing items for IKEA
Membership
TPM JISHU HOZEN and Training pillar member in Hindustan Motors.
 Safety committee member and actively participated in safety activities.
 Member of Deming committee for entire work culture towards Deming prize.
 GM ‘S QSB Vice chairman at he tabors and continental engines limited.
 Vice Chairman of Safety committee.
 MR For TS -16949 And ISO-14001 & OHSAS 18001
 Coordinator of:
o QC implementation.
o TPM Coordinator.
AREAS OF EXPERTISE

2. Manufacturing Operation
 Strategic planning of complete manufacturing operations ensuring smooth functioning of the plant to achieve &
targets as per quality / Productivity norms.
 Creating and implementing of various standards & process. Conducting technical interactions with clients in
face-to-face meetings.
 Managing activities right from the conceptualization stage to the execution; involving finalization of technical
specifications, tendering, procurement, scheduling, progress monitoring, erection, testing & commissioning,
site management, manpower planning.
QMS Implementation
 Implementing quality management systems for QS 9000, ISO 9001, TS16949, ISO 14001 & OHSAS 18001,
 Preparing & implementing quality assurance program appropriate to the specific product manufactured.
 Conducting all activities necessary to verify confidence in the quality of the process used to manufacture
finished product. Conducting SPC analysis & Pareto analysis for in-house rejection & reworks.
Process Validation
 Ensuring process validation by establishing documented evidence which provides a high degree of assurance
that a specific process consistently produces a pre-determined specifications and quality characteristics.
 Managing written procedures for production and process control designed to assure that the products have the
identity, quality, and purity they purport or are represented to possess.
 Establishing control procedures to monitor the output & validate performance of those manufacturing
processes responsible for causing variability in the characteristics of in-process material and the product.
 Initiating, implementing, and controlling written manufacturing specifications and processing procedures to
assure that the process conforms to its original design or any approved changes in that design.
Process Enhancement & Cost Control
 Identifying scope for:
o Implementation and monitoring of technological changes to enhance productivity.
o Modifications in equipments, process flow, working practices, consumables, power etc for
controlling & reducing conversion cost per unit produced.
 Executing cost saving techniques / measures and modifications to achieve substantial reduction in O&M
expenditures and work within the budget.
Inspection & Testing
 Implementing:
o Inspection test plan and QC plan for various jobs, incoming material inspection report.
o Experimental procedures for analysing the products.
 Performing inspections to ensure products are developed in compliance with pre -set technical specifications
Maintenance/ Operations
 Planning and effecting preventive maintenance schedules of various machineries and instruments to increase
machine up time and equipment reliability.
 Proactively identifying areas of obstruction/ breakdowns and take steps to rectify the equipments through
application of trouble shooting tools.
 Imparting continuous on job training to the subordinates to enhance their operational efficiencies.
Skill Set
Process:
 Cam shaft, Conrad, Crank shaft, Cylblock, Cylhead machining, Analysis of casting components, grinding
process, injection moulding .ball joints, Draglink assemblies.
Techniques:
 OEE, TPM, KAIZEN, 5S, FMEA, SPC, SQC, MSA, APQP, PPAP, 7QC TOOI'S, 8D, Lean Manufacturing.
ORGANISATIONAL DETAILS.
July ,14 on words working in Alicon cast alloys limited as a DGM Quality for four units lpdc and gdc along
with machining division.
Major customers are Bajaj, Mahindra, Honda,Maruthi.
April 2011 to 2014 July ,14 worked in in continental engines limited as a Hod quality reporting to CEO.

3. Continental engines limited is a cylinder head manufacturing unit
Continental Dealing with the customers like Eaton,paiggio,Navistar,VM Motori,Articcat,Damelr, Hd,volvo
Nissan, like more than 20 export customers and Domestic customers.
The Turnover of three plants 300 cores, with 1500 employees.
Present Role I am plying.
Handling of three plants system
Customer response for three plants .
Handling of supplier quality dept dealing with more than 60 vendors.
Handling of NPD products of three plants.
Co ordination the training s along with HR.
In process, final product audits.
Achievements.
Segregation charges at customer end reduced from 75 lakhs per Anum to 28 laths.
Customer complaints reduced from 82 to 26 per annual
Manpower in QA reduced by 10%
CMM inspection delay time reduced by 8 %to 2%.
End to end rejection reduced from 22 % to 6%.
Quality rating of Navistar improved from 82 %to 94%.
Quality rating of Itl improved from 65% to 95%.
Quality rating of Eaton improve from 70% to 88%.
Successfully passed following audits.
Volvo, Renault Nissan, Harley Davidson
Re certification for Ts-16949 for three plants by TUV
Co coordinating three plants MR Activities.
Success fully achieved new Business Audits of Hardly Davidson, Volvo, Mercury, Futon,
Foundry rejection bring down from 20% to 6%.
From 2009 on words worked in speed OMAX as a Hod quality.
Speed OMAX is the company manufacturing the like chain case,saree Guard, pedal gear
Home furnishing items for IKEA.
Achievements
C0PQ reduction done by 20%.
Eliminate the segregation charges.
Established poke-yoke at weld shop and paint shop & press shop.
Kaizens and qc concept established for entire plant
Vendor quality rating improved from 52% to 80%from Hero Honda.
Multi skill activity developed for Home furnishing team and automobile team.
OCT ‘06 TO OCT-09 QH TALBROS as A Senior Manger – Q.A
Major customers for Talbors Maruthi Suzuki, Asoka Leyland and Tata Motors, Eicher, force
motors
Carror India .
Notable Deliverables.
 Resolving entire corporate customer complaints .
 Reduced 15 % manpower in Q.A Dept.
 Multi skill’s developed.
 Developing new projects like Kubota, Tata Hendrickson Projects ,GM
 Brought down the:
o Rejection to 200 PPM and made 20 vendors as a DOL.
o Internal rejection ball pin & housings to Below 500 PPM.
o Assembly rejection

4. Inspection. delay time controlled. by developing various inspection fixtures.
 Introduced the:
o Quality circles concept through quality circles and saved Rs 3.5 Corers.
o 45 poke yokes in the shop floor .
o 200 Kaizens implemented.
 Implemented 230 Kaizens in shop floor and saved Rs. 50 lakhs
 Imparted continuous trainings all levels.
 GM QSB Implementation.
 Tpm Heading quality pillar and safety and health. Pillar
 Leader of manager model Machine .
 Handling supplier quality assurance department.
Lot wise communication system developed.
 Supplier audits
 Reduce the incoming inspection time by developing the various fixtures.
 Effective audit systems developed at vendor end
 Frequent vendor meets conducted to develop the communication system.
Jul’03- Sep’06 Continental Engines Ltd., Bhiwadi as A Manager cellular concept.
The organisation is manufacturing multi-types of Cylheads.
Major customers LIKE payakan, Nissan, piaggio, ITL, MAHINDRA&MAHINDRA, HINDUSTAN MOTORS.
Involved in establishing of Makino machining line for Lean Manufacturing Concepts.
 Imparted training on 7 Q.C. TOOL'S / SPC / 5 S. / KAIZEN / 8-D problem /3M to the company employees.
 F.M.E.A. for all models of Cylheads.
 Lean management for Toyota & Mitsubishi & Nissan Lines.
 Handling 42 vendors and made 10 vendors as DOL item by implementing quality tools.
 Reduced the rejection rates from 20% to 0.5 % by using TQM techniques.
 Saved Rs. 50 lakhs through Kaizen per year.
Nov’93- Jul’03 "Hindustan Motors Limited" Indore as A module leader MFG in engine plant
Notable Deliverables
 Played pivotal role to develop CYl.BLOCK & Cyl. Head & cam shaft for lancer car & General motors and cam-
shaft & crank shaft for Lancer & General motors.
 Productivity improved in cam shaft cell by u lay out concept.
 Involved in up-gradation of Isuzu MPFI Engine.
 Brought down the inspection delay time below 10% by developing various inspection fixtures & gauges for
lancer & General motors & FORD - IKON.
 Handled control plans of all 5 c's of Lancer G.M. FORD; Isuzu. lancer
 Executed the initial phase of production enforcing the S.O.P standards, trained the staff, formulated
companywide objectives & worked towards achieving the same.
 Established Marposs gauging system in process and final inspection stages.
 Implemented FMEA and APQP for Lancer , General Motors for vendors
 Made as cam shaft cell as demo cell in all as pacts, 10000 cam shaft produced in financial year 2001-2002.
(high production in HM history)
 Expertise in phosphate process for Engine components.
 Worked in VRD department.
 Experitision in cam grinding & crank shaft pin grinding.
Previous Assignments
Oct’89- Sep’93 Malhothra Shaving Products Ltd. Hyderabad as a Q.A INCHARGE.
Mar’88- Aug’89 Vani Machine Tools Ltd. Hyderabad (AP) PRODUCTION SUPERVISOR.

5. MAJOR SUPPLIER OF CAPAL GEAR BOX, ORDINANCE FACTORY FIXTURES
B..H.E.L OIL PUMPS.
TRAININGS
Successfully attended the professional trainings on:
 Quality controls and management from F.T.I. Bangalore (Duration 20 days).
 Practical approach to stastical process control for industries from Indore management association (one week).
 Tool management for future success at WIDIA India Ltd. Bangalore (one week)
 CNC program and application at softek computer education.
 Qualified the Auditor course for Q.S. - 9000. & TS-16949&OHSAS.
 Qualified auditor for TPM.
 Attended;
o GM QSB workshop.
o Positive skills & proactiveness trainings through ECS consultancy.
PROFESSIONAL QUALIFICATION .
Diploma in Mechanical Engineering from S.V.K.P. (A.P) 1984- 1987
Post Diploma in Mechatronics from C.I.T.D. Hyderabad. (AP) 1989
PERSONAL DETAILS
Date of Birth : 14th
January 1968
Address : M-118, Ashiana Aangan , Bhiwadi -301019.
Salary drawn : 18 lacks.
Salary : Negotiable
Notice period : One Month.