Mohammad Faisal

Experience

1. Quality Engineer

   Ford Motor Company

   Apr 2023 — Present · US

   Enhanced FTT by 18% and reduced warranty claims by 25% for Explorer and Aviator models through targeted process improvements.• Conducted over 50 ISO 9001-IATF 16949 audits, achieving a 100% compliance rate and operational excellence.• Led Root Cause Analysis (RCA) and implemented Corrective and Preventive Actions (CAPA), reducing production defects by 15% and minimizing operational inefficiencies.• Conducted Failure Mode and Effects Analysis (FMEA) to identify failure points, implementing preventive measures that improved product reliability by 20%.• Oversaw Statistical Process Control (SPC) and Process Capability Analysis, optimizing manufacturing processes and achieving a 25% reduction in process variability.• Developed and managed 8D, PFMEA, Control Plans, SPC, MSA, PPAP, and APQP tools, ensuring robust quality control systems and reducing defect occurrences by 30%.• Implemented AI MAIVS Vision System, improving defect detection rates by 35% and decreasing inspection time by 20%.• Delivered comprehensive MDQOS requirements for Powertrain Subsystems, streamlining processes and enhancing throughput by 15%.• Implemented and sustained Lean Manufacturing and Six Sigma methodologies, achieving a 30% reduction in waste and a 15% improvement in process efficiency.• Authored, revised, and maintained detailed process sheets, including updated cycle line layouts to streamline operations and enhance productivity.• Utilized advanced virtual tools to evaluate new model designs, ensuring manufacturability and efficiency in high-volume production.• Streamlined workflow by updating 150+ process sheets and implementing new cycle line layouts, improving productivity by 20%.

Education

• Osmania University, Hyderabad

  Bachelor of Engineering - BE

• Trine University

  Master of Science - MS