Sustenance Quality Lead

About this role

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