Sundara Rajulu Yanappa

• Result Oriented Senior Management Quality, Operational Excellence & Certified 6 Sigma Black Belt with an extensive experience of 31 years in Supply Chain and Manufacturing.A creative,highly motivated leader with Management,Operational Excellence(Lean 6 Sigma, Kaizen Blitz & TPM),Quality,Metallurgy,Supplier Development and Supplier Quality,New Product Introduction(NPI) and Global Purchasing Functions in 3 Global MNCs,4 Auto OEM JVs and 2 Indian MNCs

• Domains: Automotive, Engines, Earthmoving, Machine Tools and Power Electronics (UPS Products)

 Quality

 Organizational Safety and Quality KPIs/KRAs/Critical Success Factors(CSFs)
• Created and Established Quality Organization,Organizational Safety and Quality KPIs(Safety-MIR,SR and Quality- First Pass Yield, DPU,plant Quality ppm,Supplier Quality ppm,Annual Failure Rate(AFR),COPQ & Monthly Global Quality Dashboard MIS Reporting for multiple 6-9 plants

 Customer Quality
• Handled more than 500+Multiple Products(which includes Automotive,Engines,Earthmoving machines,Machine Tools and UPS) and 200+ key Strategic Customers(Global and Local)
• Improved Customer Quality Failure Rate ppm,reduced In-warranty Cost & Cost Of Poor Quality(COPQ)

 NPD/NPI Quality
• Facilitated new product development initiative with key focus on Quality, Cost & Delivery; Approving components and products- Released to Manufacturing and Sales (RTM and RTS) in conformance to Tech.Specifications

 Supplier Quality Management
• Having rich experience of 18 years in Supplier Quality Management(which includes Supplier Development, Supplier selection and approvals ,Localization,Tracking of Supplier Performance Management measures like QCLDM-Quality,Cost,Logistics,Development and Management,Root Cause Analysis and CAPA Monitoring ) & Supplier Focus Audits etc.

• 200+ companies have been evaluated through QCLDM Assessments for the capabilities of suppliers
(Foundries, Forging companies,Sheet Metals,Polymers, Plastics and other commodities) with respect to R&D
Capabilities, precision product quality standards, plant and equipment and business processes

• Handled 500+ Suppliers (Global and Local) & developed more than 10,000 Components of various commodities through APQP and PPAP Process of AIAG Automotive Standards over the past 18 years in Manufacturing and Supply Chain

 QMS & EOHS(QHSE)
• 20 Years of experience as a Internal Quality Auditor and Auditee for Global and Local Audits in ISO 9001,QS9000,ISOTS16949 Standards

• Country Champion / Management Representative(MR) at APC By Schneider Electric for Documentation, Auditing ,Implementation and Sustaining of Quality Management Systems(QMS) & Supporting MR for Implementation of
EOHS ISO 14K & OSHAS ISO 18K & Conducted Management Reviews with Leadership periodically

• Experience in interfacing with 3rd party Certification Bodies - BVQI,TUV,NQA and DNV for the past 20 years for Audits and Final Certifications

• Experience in facing > 200 International and Domestic Customer audits across all continents in the world
• Experience in IMS ( ISO9001,14001 and 18001 standards ) from Schneider Electric

 Metallurgy Quality Assurance including Welding Quality
• As a OEMS Customer ,closely worked for the past 20 years with Steel mills,Forging companies, Iron and Steel
Castings Foundries in India for Localization and Development of various grades of Steel products,Forging
steel products and Foundry Steel Castings products.This includes Research and Development to use
alternate and Cost saving materials to reduce failures,Process Improvements,Defect reductions,Customer
Complaints handling, Failure investigations and Continual Quality Improvements

• Have strong knowledge and experience in Metallurgy,Steel making, Forge process controls,Hot and Cold Forging,
Metallurgy,Heat treatment,Fabrication,Welding processes and NDT for the components used in automotive
, Engine,earth moving,industrial and machine tools domains

• An experienced Senior Metallurgist having hands on experience in Metallurgy and Metallurgical labs - Expertise in evaluation of Dimensional quality,chemical,mechanical and metallurgical properties,Internal Soundness of various graded steels,Welding Metallurgy,Forgings and Castings using Microscopes,Image analyzer, Spectrometer,UTM & Non-Destructive Testing(NDT)

 Operational Excellence

• Caterpillar USA Trained Project Sponsor,Trained and Certified 6 Sigma BB and GB in DMAIC and DMEDI (DFSS) and Over 10 years utilizing Lean 6 Sigma (LSS) tools and methodologies,13 years as a Change Management Leader Plus Schneider Electric Trained Lean Practitioner and Schneider Production System Auditor

• Trained, Coached and Mentored more than 1200 participants(YBs,GBs,BBs,Sponsors,Managers and Suppliers) across Asia Pacific Region

• Led high impact projects through Lean 6 Sigma in coordination with cross functional teams/departments and achieved LEAN:Productivity increased 30%,On Time Delivery improved 20%,OEE improved 10%,Customer Complaints reduced 28%, NPI process lead-time reduced from more than 1-year to less than 6 months ,Kanban projects(Finished goods inventory Reduced 50% and Production Cycle Time reduced 50%)

• Executed more than 300 Pokayoke and 450 Kaizens over the past 8 years

• Cost Reduction- Led over 60 Lean Six Sigma/Lean/Kaizen projects(related to Customer Complaints Resolution,Localization,Strategic Sourcing,Resourcing,Value Engineering,LCC Sourcing in 4 Auto OEMs,Cummins, Caterpillar, Schneider Electric, Bharat Forge and Bharat Fritz Werner (BFW) & demonstrated a track record of >30M US $ in annualized cost savings over the past 18 years

• Have Global exposure with Manufacturing Facilities,Design Centers,Stake Holders and Corporate Leadership Teams(Visited 13 Countries- North America,UK,Europe and Asia Regions) worldwide/Conducted Workshops for Synergy,Collaborations, Replications, Horizontal deployment, Product Transfers, Continual Product Quality Improvement

• Served as Head of Quality and Operational Excellence (as GM,VP and Director Senior Management Leadership roles) for the last 8 years in Indian and Global MNCs for 6-9 plants in Multi-locations & Handled a team size of more than 140 Head Count(HC)

• Holds B.Tech degree in Metallurgical Engineering, from premium institute,NIT, Warangal,India