رافيكومار Thiruchitrambalam

1. Leading and managing high-potential teams for various Aerospace and Defense projects, including those in defense public sector undertakings. Liaising with SSQAG, R&QA, DGAQA, CABS-QCD, ASL-DRDL, BEL, ADA, ADE, ECIL, HAL & NAL.
2. Outlining a technological vision and implementing technology strategies that align with the sectors unique requirements, while ensuring that the quality and technological resources meet the companys business needs.
3. Implementing, managing, and maintaining quality management operations standards for Aerospace and Defense to provide the industrys best practices for both suppliers and customers throughout the entire product life cycle, including early product development and pre-production phases, and the post-production service phases.
4. Maintaining a customer-focused outlook and aiding in delivering projects to customers while ensuring that all regulatory standards specific to the Aerospace and Defense sector (MIL, JSS, ASME, DO, ASTM, IPC, ISO, SAE…) are met.
5. Managing quality budgets and time frames to ensure timely delivery of projects with the highest level of quality.
6. Establishing, implementing, and maintaining the Quality Management System (QMS) in accordance with the requirements of AS9100D.
7. Ensuring that the QMS is effectively communicated, understood, and implemented throughout the organization, including suppliers and subcontractors.
8. Providing leadership and direction to the Quality department and other relevant functions, such as Manufacturing, Engineering, and Procurement, to ensure that quality objectives are established and achieved.
9. Defining and implementing quality policies, procedures, and practices in accordance with AS9100D, customer requirements, and industry best practices.
10. Developing and maintaining a quality control plan that identifies the critical quality characteristics of the organizations products and services, as well as the methods, techniques, and tools for controlling and monitoring these characteristics.
11. Ensuring that all quality records, such as inspection reports, non-conformance reports, corrective action reports, and customer feedback, are maintained in accordance with the requirements of AS9100D.
12. Conducting internal audits to assess the effectiveness of the QMS and identify areas for improvement.
13. Ensuring that all corrective actions resulting from non-conformities, customer complaints, or other sources are taken promptly and effectively.
14. Ensuring that all employees are trained on the QMS and the organizations quality policies and procedures.
15. Representing the organization in all matters related to quality, including customer audits, regulatory inspections, and certification audits.
16. Staying on top of quality trends and developments in the Aerospace and Defense sector, including the latest tools and techniques for ensuring the highest quality standards.
17. Ensuring that all quality practices adhere to statutory and regulatory standards, including those specific to the Aerospace and Defense sector, as well as meeting customer-specific requirements.

1. Business development & managing Omnex Middle-east as standalone profit centre.
2. Currently involved in Lean Six Sigma project as Project Manager in Kuwait Oil Company in all its 9 Directorates through Performance Management Systems & Balanced Scorecard.
3. Experienced in leading team of quality & multi disciplinary professionals towards successful completion of projects. Managing, motivating, coaching and mentoring direct reportees to a high level of capability.
4. Successfully managed & completed more than 230 consulting projects independently/ leading multinational teams in both Manufacturing & Services (Such as Oil & Gas, Automotive, Aviation/ Aerospace, Marine/ Shipping, Retail, Apparel/ Textiles, New Materials/ Fibres & Composites, Banking & Financial, BPO, Chemical, Commercial Vehicle, Manufacturing, Semiconductor and Transportation & Logistics).
5. Implementation experience of Integrated Management System (Integrating multiple Systems).
6. Experienced in conducting independent as well as supplier audits and evaluation of supplier/ organisations capability in Business/ Manufacturing/ Design & Project/ Process for API ISO 29001, AS 9100C, ISO 9001 (with specific requirements of ISO/TS 16949), ISO 14001 & OHSAS 18001.
7. TOOLS AND ITS KNOWLEDGE/ COMPETENCY
a. Develop organisations/ suppliers to achieve the desired PPM levels by training and implementation of Quality tools like Effective Problem Solving, FMEA, SQC techniques and other QC tools.
b. Knowledge on usage of All quality equipments and Quality assurance tools.
c. Conducted more than 1400 executive training programs on modules such as TQM, Lean Manufacturing, Six Sigma, SA 8000/ TL 9000/ ISO/TS 29001/ APQP/ PFMEA/ QFD/ MSA/ SPC/ DOE/ ANOVA/ 5S (World Class Work Environment) and many more subjects as lead/ supporting faculty.
d. Manufacturing Knowledge - Machining, Welding, Heat Treatment, Plating, Powder Coating, Soldering and Casting
e. Knowledge on metallurgical testing both destructive and Non-destructive tests in reference to ASTM.
8. Expert in Loss Function in Quality Engineering, Operations Management, Process Improvement & Business Process Reengineering.
9. Experience in developing New Product Development using APQP/ manufacturing process plans/ control plans and inspection plans. Experience in identifying & implementing Quality and vehicle safety requirements in accordance with company needs, based on current regulations and state-of-art product development.
10. Experience in dealing with overseas customers/ Multinational & Multicultural organisations. Project works carried out in countries such as Bahrain, China, India, Ireland, Kuwait, Malaysia, KSA, South Africa, Taiwan & UAE.
11. Worked with the OEMs such as Ford, Ashok Leyland, Volvo, Daimler, Force Motors, Skoda and TVS Motors as part of projects & trainings.

1. Corporate Management Representative for Quality Assurance Management Systems.
2. Managing the Strategic Decision through Decision & Risk Analysis.
3. Co-ordinated the automation of the sales, finance, production, purchase and quality functions.
4. Co-ordinated the relocation of back office operations (order entry & accounting) from Limerick, Ireland to Chennai, India in association with the respective functional heads.
5. Accomplished Half Million-Euro savings within 6 months in materials consumption & cost reduction.
6. Accomplished € 50, 000 savings by No cost inventory database creation & its effective utilisation.
7. Simulated the manufacturing process to optimise the resource allocation and optimised the product mix to maximise the sales revenue by 20% using SIMPROCESS.
8. Implemented simplified SHE system in 6 months BS&B Safety Systems.
9. Implementation and maintenance of OHSAS 18001: 1999, ISO 9001: 2000, WCM (TPM & TQM).

1. Management Representative of the company for ISO 9001: 2000 implementation & managed the business processes, Quality management activities and successfully coordinated the certification by BVQI, UAE.
2. Implemented Six-Sigma and successfully completed more than 50 improvement projects within 6 months through cross functional team management.
3. Streamlined Business Processes Flow & its Procedures for all functions in the organisation in co-ordination with all the key functionaries and incorporated the Continuous Improvement principle into the QA Management System.
4. Organised training programme for all levels of management in ISO 9001: 2000 QAMS awareness, TQM, Continuous improvement and Internal Quality Audit.
5. Managed the User Acceptance Testing for the web site design & its functional integration with the Enterprise Resource Planning, CRM, CIM and Site-server databases.
6. Monitoring the Inventory and Logistics Cycle for continuous improvement.
7. Implemented basic COPC 2000 standard for the content development & CRM help desk.
8. Prepared the functional logic for the customised CRM & CIM (Customer Relations Management & Customer Interactions Management) application.
9. Co-ordinated the web content development activities (defining the standard for data entry and standard for classification and categorisation for online catalogue development)

1) Worked in Process Improvement (in Precipitation Plant) project in Hindustan Aluminium Company, Renukoot, Uttar Pradesh, India.
2) Worked in World-Class Manufacturing implementation (involves 12 subcommittees, regular auditing and streamlining the activities of the subcommittees) project in Grasim Industries, Harihar, Karnataka, India.
3) Worked in ISO 9000 (documentation, implementation, Initial & preliminary assessment and Training) Projects in Marine Engineering & Research Institute, Calcutta, West Bengal, India and IML-Auto Components Division, Hosur, Tamilnadu, India.
4) Assessed and reviewed Quality System Documentation With respect to the International Standard ISO 9001: 1994(E) and ISO 9000-3:1991(E) for Simplex Solutions Private Ltd. (Software Company), Bangalore
5) Cumulative Consultative experience of 1270 man-hours.
6) Conducted 14 Training programs (190 Hours of training) on Modules such as ISO 9000/ SPC / IQA / 5S as Lead / Supporting Faculty.
7) Certified Auditor/ Lead Auditor for ISO 9000 QMS by the Centre for Quality Excellence, UK.
8) Awareness of SEI-CMM Concepts and Six Sigma Requirements.
9) Taught “Strategic Quality Management” for the ISEC students in ISI Calcutta, India.
10) Presented a paper titled Quantitative analysis in Business Process Reengineering in the national conference on Business Competitiveness and Growth Through Quantitative Methods August 6-8, 1998, organised by Indian Statistical Institute, Chennai, Tamilnadu, India.
11) Gave seminar on the topics Business Process Reengineering in Indian Context and Process Benchmarking in Indian Statistical Institute, Calcutta, West Bengal, India.
12) Paper titled Methodology for Business Process Reengineering was accepted for presentation in INFORMS conference on Delivering to the Global Customer organised by Institute for Operation Research and Management Science, Cincinnati, United States of America, in May 1999.
13) Communicated a Paper titled Methodology for Business Process Reengineering to the quarterly journal of Indian Institute of Management, Bangalore, Karnataka, India (under review).
14) Attended Transition Programme for Lead Auditors for ISO 9001: 2000 Quality Management System organised by BVQI, Kuwait.
15) Attended Lead Auditor Programme for ISO 9000 QAMS Organised by NVT Centre for Quality Excellence, India.
16) Attended Intensive Expert Development Programs on ISO 9000 & QS 9000 and SPC & DOE conducted by Indian Statistical Institute, Chennai, Tamilnadu, India.
17) Attended Knowledge Development program on Human Aspects of Quality (Organisational Behaviour and Values & Beliefs in Organisation) organised by Industrial Engineering Department, College of Engineering Guindy, Anna University, Chennai, Tamilnadu, India.
18) Independent Project Consultancy (Project Scoping, planning, Process Improvement Study & Implementation, Statistical Analysis and Inference), Research & Development, Training, Teaching and Promotional Work.

Online & Offline Quality Control, Work-Study and Fault Proofing

Extensive experience in implementing and managing end-to-end quality control systems across manufacturing and engineering environments, covering both online (in-process) and offline (final and lab-based) quality assurance activities.

Online Quality Control:

Established robust in-process inspection systems to monitor product quality at critical stages of production.

Implemented real-time quality monitoring, control plans, and process audits to ensure early detection and containment of defects.

Led deployment of Statistical Process Control (SPC) techniques to maintain process stability and capability.

Coordinated with production teams to drive first-time-right (FTR) and reduce rework and rejection rates.

Offline Quality Control:

Managed final inspection, testing, and validation activities including dimensional, functional, and environmental testing.

Oversaw laboratory testing, failure analysis, and root cause investigations to ensure product compliance with specifications and standards.

Ensured adherence to customer requirements, regulatory standards, and documentation (test reports, certifications, traceability).

Work-Study (Productivity & Method Engineering):

Conducted detailed time and motion studies to optimize manpower utilization and improve operational efficiency.

Designed and implemented standard operating procedures (SOPs) and work instructions for consistent execution.

Identified bottlenecks and implemented line balancing and process improvements to enhance throughput.

Fault Proofing (Poka-Yoke):

Designed and implemented error-proofing mechanisms (Poka-Yoke) to prevent defects at source.

Introduced preventive controls in processes, tooling, and fixtures to eliminate human errors.

Led cross-functional initiatives to reduce defect occurrence through root cause analysis (RCA), FMEA, and corrective/preventive actions (CAPA).

Impact:

Significant reduction in defect rates, rework, and customer complaints

Improved process capability, productivity, and operational efficiency

Strengthened quality culture through proactive and preventive approaches