What you will do:
The Sustenance Quality Lead is responsible for overseeing post-launch quality performance across manufacturing, supplier ecosystem, and field operations. This critical role ensures sustained product reliability, manages field failure containment, drives root cause resolution, and maintains quality system compliance (IATF 16949, ISO 9001). The role bridges production realities with field performance to achieve 100% customer satisfaction.
Responsibilities
1. Sustenance Quality Strategy & Governance
- Develop and own the Sustenance Quality roadmap aligning manufacturing quality, supplier quality, and field quality functions
- Establish KPIs across all three functions:
- Conduct monthly Sustenance Quality Reviews (SQRs) with cross-functional leadership
- Own 8D/5-Why containment and permanent corrective actions for field failures
- Maintain IATF 16949 compliance for all sustenance processes and documentation
2. Manufacturing Quality Oversight
- Ensure manufacturing quality team delivers Cpk >1.67 for critical characteristics
- Review and approve Control Plans, PFMEA, and MSA results from production
- Drive yield improvement from current baseline to the set targets through process capability enhancement
- Conduct Layered Process Audits (LPAs) quarterly across all production lines
- Manage production non-conformance (NC) reduction to meet the targets
3. Supplier Quality Management
- Lead supplier performance reviews; maintain supplier scorecard (Quality, Delivery, Cost, Tech)
- Implement supplier development plans for chronic performers (process audits, training etc.)
- Approve PPAP submissions for all new/changed components
- Achieve supplier incoming quality targets through robust incoming inspection strategy
- Conduct annual supplier audits or top strategic suppliers
4. Field Quality & Customer Satisfaction
- Analyze field failure data (warranty, service center returns) using suitable analysis techniques
- Establish field failure containment gates as per the set standards
- Coordinate cross-functional Corrective Action Teams for field quality issues
- Achieve Field MTBF targeted hours through design/process improvements
- Maintain customer satisfaction target score through timely quality issue resolution
5. Team Leadership & Development =
- Mentor and develop Manufacturing, Supplier, and Field Quality leads and Engineers
- Conduct quarterly performance reviews and individual development plans
- Foster continuous improvement culture
- Provide training to employees on IATF 16949
The ideal candidate requires:
- B.E./B.Tech Mechanical/Electrical 15-20 years quality experience in automotive/EV manufacturing
- 5+ years leadership experience managing multiple quality functions
- IATF 16949 Lead Auditor certification (or equivalent)
- Proven track record reducing field failure rates
- Hands-on experience with PPAP, APQP, FMEA, Control Plan, MSA, SPC
- Six Sigma Green Belt (Black Belt preferred)
Strongly Preferred:
- Experience in EV battery, power electronics, or high-voltage systems
- Warranty analysis experience using suitable analysis techniques
- VDA 6.3/VDA 6.5 auditor qualification
- Core Tools Master Certification (AIAG)
Key Competencies
- Technical: Deep understanding of manufacturing statistics (Cpk, GR&R, Gage R&R), reliability engineering (Weibull, MTBF), quality systems (IATF 16949)
- Leadership: Cross-functional influence without direct authority, team development, change management
- Analytical: Root cause analysis mastery (8D, 5-Why, Fishbone), data-driven decision making
- Communication: Executive presentations, supplier negotiations, customer issue escalation management
What We Offer
- Opportunity to shape quality strategy for next-gen EV products
- Direct impact on field customer experience and brand reputation
- Leadership role spanning manufacturing, supply chain, and aftermarket
- Collaborative culture with validation, design, and manufacturing teams
