Ajay Khosla
Gates Corporation
20
years of professional experience
1
Certification
Experienced professional with over 17 years of proven experience in product/process innovation, process engineering, continuous improvement, quality assurance, operations management, process excellence, product/process development etc. across global industrial sectors. Known for delivering patented innovations and multimillion-dollar cost savings in manufacturing. An ASQ Certified Six Sigma Green Belt with extensive experience in delivering continuous improvement projects related to Yield, scrap reduction, process improvement, new product development and introduction. Skilled in leading cross-functional teams and driving change in multinational environments.
Work History
Manager – Process Development & Innovation (FP and PT)
2 Years 11 Months- Leading the development of innovative processes and products in the power transmission segment.
- Leading the development of innovative processes and products in the fluid power segment. Patent WO 2026/122965 published with two additional patent applications in progress.
- Drove the vision, strategy, and thinking methodologies that fostered innovation in FP and PT products.
- Driving technical strategy and process innovation initiatives aligned with global product roadmaps.
- Recognized improvement opportunities to enhance efficiency and reduce costs. and modifying existing processes and products across fluid power and power transmission plants using optimization tools and methods.
- Collaborating with cross-regional teams to identify bottlenecks, optimize output, and reduce costs.
- Identifying improvement opportunities and modifying existing processes and products across fluid power and power transmission plants using optimization tools and methods.
- Developing standardized global processes across FP lines, including HFM, Spiral, and Pole-built lines.
- Facilitating CRB (Change Review Board) meetings to review project capabilities and results.
- Supporting Gen 1 and Gen 2 product launches through process definition and qualification controls.
- Leading the introduction of new systems and procedures to support production targets.
- Performed research to develop improved production methods and recommendations. into production methods and recommending and implementing improvements following successful trials.
- Conducting RCAs to reduce internal rejections and initiating defect-reduction projects across plants.
- Supervising and guiding a team of four engineers working on high-impact innovation projects.
Manager – Process Engineering, Innovation & Continuous Improvement and Quality Assurance
11 Years 3 Months- Directed plant-wide DMAIC and other continuous improvement projects, realizing significant cost savings.
- Launched platform for managing new product/process changes, enhancing cross-department efficiency.
- Recommended and implemented operational improvements, optimizing various processes for better performance.
- Initiated and completed VAVE projects, focusing on productivity enhancement and defect control.
- Managed manufacturing process strategies and monitored key process indicators for proactive issue resolution.
- Spearheaded localization of tooling resources, decreasing import dependency and securing supply continuity.
- Conducted RCA, CAPAs and 8Ds to reduce internal rejections and customer complaints.
- Led regular updates to documentation, including FMEAs and Control Plans, and incorporated changes resulting from corrective actions.
- Assisted in the continual improvement of the plant’s QMS.
- Conducting internal and external audits and measuring the effectiveness.
- Developed validation plans and led teams responsible for validating new machinery within the plant.
- Led the development and execution of patented MXG/MXT product lines in India, aligned with global strategy.
- Championed process capability studies (SPC) and implemented data-driven solutions to eliminate special causes of variation.
- Maintained and enforced safety, health, and environmental compliance as per policies.
- Supervised and guided a team of 3 engineers working across different projects.
Deputy Manager – Quality Assurance & QS
1 Year 4 Months- Implemented and sustained QMS to ensure compliance with TS 16949 and ISO 9001:2009 standards.
- Spearheaded Six Sigma Green Belt project to eliminate internal diameter variation in hollow shafts.
- Led root cause analysis (RCA) for internal/customer complaints using 7 QC tools and DMAIC methodology.
- Coordinated CAPA closures and reviewed quality documentation to ensure adherence to quality standards.
- Coordinated corrective/preventive action (CAPA) closures and reviewed quality documentation.
- Supervised quality team for final inspection and incoming quality control, ensuring product quality and compliance.
Executive – Quality Control
1 Year 1 Month- Led product and process audits to assess adherence to quality and process standards.
- Conducted Measurement System Analysis (MSA), SPC studies and managed CAPA processes.
- Led root cause analysis (RCA) for internal/customer complaints using 7 QC tools.
- Collaborated with internal teams to address non-conformities and implement preventive actions.
- Supported implementation of 5S, Kaizen and Autonomous Maintenance initiatives.
Quality Engineer
2 Years 7 Months- Managed receipt inspection, supplier quality agreements, and resolved customer complaints through CAPAs to ensure quality standards.
- Executed layout inspections, developed gauges, and calibrated for TS 16949 compliance to maintain regulatory standards.
- Performed audits and coordinated supplier quality performance reviews.
- Managed quality documentation for OEM projects across India and Europe (Tata, VW, Daimler, Ford, etc.).
- Oversaw quality documentation for OEM projects across India and Europe (Tata, VW, Daimler, Ford) to ensure alignment with project requirements.
Education
Bachelor of Technology - Mechanical Engineering
Skills
Quality Assurance & Quality Systems
Process Excellence
Continuous Improvement
Lean Manufacturing
Operational Excellence
Manufacturing Engineering
Process Engineering
Process Development
Product Development
New Product Introduction (NPI)
Lean Six Sigma
DMAIC
Kaizen
RCA
CAPA
SPC
MSA
FMEA
Control Plans
Validation
OEE Improvement
Yield Improvement
Cost Reduction
ISO 9001
IATF 16949
Internal Auditing
Cross-functional Leadership
Team Leadership
Change Management
QMS
Accomplishments
- Delivered USD 3.9 million in measurable manufacturing savings through numerous continuous improvement projects.
- Reduced scrap from 2.7% to 0.8% through structured RCA, statistical analysis and process optimisation in the HFM line.
- Improved production capacity by 800 meters/day while increasing manufacturing efficiency.
- Improved braider productivity by 10%, winning the Northwest Qualtech Award in one of the biggest northeast competitions of Continuous Improvement.
- Increased manufacturing throughput by 50% through tandem braider implementation.
- Extended mandrel life from 14 to 19 cycles which further reduced the short length scrap, reducing tooling costs by introducing local vendors besides ensuring Quality.
- Led development and industrialization of globally adopted manufacturing technologies like usage of Co-extrusion methods.
- Co-inventor of published international patent WO 2026/122965 with additional patent applications pending.
- Initiated and led the standardisation of best-practice manufacturing processes across multiple plants, improving the efficiency of specialized operations such as rewinding and mandrel preparation.
- Led the development and introduction of patented MXG/MXT products (Legacy Products) at the Indian plant; initiated process and product improvements to enhance performance and earned the Gates C. Charles Award (Company’s highest accolade).
Certification
- ASQ Certified Six Sigma Green Belt-ASQ
- Six Sigma Black Belt – QT&T
- ISO/TS Internal Auditor – TUV SUD
Timeline
Manager – Process Development & Innovation (FP and PT)
Gates Corporation
08.2023 - CurrentRead More
Manager – Process Engineering, Innovation & Continuous Improvement and Quality Assurance
Gates India Pvt. Ltd.
04.2012 - 07.2023Read More
Deputy Manager – Quality Assurance & QS
TPI – Murugappa Group, India
11.2010 - 03.2012Read More
Executive – Quality Control
DCM Engineering Products Ltd.
09.2009 - 10.2010Read More
Quality Engineer
Sigma Vibracoustic India Ltd.
01.2007 - 08.2009Read More
Punjab Technical University
Bachelor of Technology from Mechanical Engineering
Read More