Poorva Aparaj
Quality Engineer | Manufacturing & Supplier Quality | Continuous Improvement | ISO 9001 Internal Auditor | CAPA | 8D | PFMEA | PPAP | Agile PLM | CAPM | Scrap Reduction | Industrial & Systems Engineering (MS)
- Role
- Quality Engineer at Rhenus Automotive
- Location
- Salem, VA, US
- LinkedIn followers
- 500 followers
About Poorva Aparaj
I am a Quality Engineer passionate about manufacturing excellence, supplier quality, and…
Experience
Quality Engineer
Jun 2024 — Present · Salem, VA, US
Led a scrap reduction initiative that cut scrap costs by 77% in Q1–Q2 2025 compared to Q3–Q4 2024, saving ~$40K by performing 8D root cause analyses, implementing corrective actions, training operators to better identify defects on the line, and escalating recurring issues to suppliers and customers.• Designed and rolled out a standardized paint defect tracking and accountability process, which reduced externally charged paint defect costs by over 60%. This resolved gaps in traceability, minimized incorrect chargebacks, and improved collaboration with suppliers and customers.• Maintained critical 100-point defect occurrences at just 3 per month in 2025, down from 20 per month in 2024, by establishing containment protocols, improving defect detection at stations, and proactively addressing field feedback with structured 8D problem solving.• Reduced 25-point defects by 44%, from 52 in Q3–Q4 2024 to 29 in Q1–Q2 2025, by creating visual quality standards, setting up defect escalation processes, and coaching operators on root cause awareness.• Performed root cause investigations on 50+ major cab line defects, delivering corrective actions through A3s, 8Ds, PFMEAs, and internal audits to drive long-term defect reduction and process control.• Supported NHTSA and ISO 9001 audits with zero major findings by performing internal process audits, cleaning up 500+ QMS documents in XERI, deactivating obsolete files, and standardizing documentation for compliance.• Created and implemented a quality training module for new hires focused on defect detection, general quality principles, and process adherence; developed station-specific defect assessment tools for operators.• Set up a defect logging process for the repair team to track and escalate supplier-related defects more efficiently, improving traceability and accountability across the line.
Education
Dr.Vishwanath Karad MIT WORLD PEACE UNIVERSITY|PUNE
Bachelor of Engineering - BE
2018 — 2022
Virginia Tech
Master of Science - MS
2022 — 2024
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