JSS Hydraulics P. Limited

Quality Engineer – Hydraulic Cylinder Manufacturing

New Delhi | India | 3 Years

In my role as a Quality Engineer at a leading hydraulic cylinder manufacturing firm, I was entrusted with ensuring the reliability, consistency, and compliance of precision-engineered hydraulic components used across industries such as construction equipment, agriculture, material handling, and industrial machinery. This experience provided me with end-to-end exposure to advanced quality systems, supplier development, and customer assurance processes, grounded in ISO 9001:2015, APQP, and PPAP frameworks.

Over the course of three years, I developed and applied a comprehensive skill set in core quality engineering, supported by a deep understanding of statistical techniques, lean principles, and Six Sigma tools to drive process improvement, reduce variation, and enhance customer satisfaction.

Key Responsibilities

Advanced Product Quality Planning (APQP)

I was actively involved in managing APQP processes from concept to production, particularly for new product development (NPD) and engineering change requests (ECRs). My role covered the following key APQP elements:

Project Quality Planning: Collaborated with cross-functional teams (Design, Manufacturing, and Procurement) to define CTQs (Critical to Quality characteristics) and risk profiles for new hydraulic assemblies.

DFMEA and PFMEA Facilitation: Supported the creation and review of Design Failure Mode and Effects Analysis (DFMEA) and Process FMEA, ensuring identification of potential failure modes, effects, and corrective actions before production ramp-up.

Process Flow Diagram & Control Plan Development: Designed process maps, established control plans, and defined critical inspection points across machining, welding, assembly, and pressure testing.

Supplier Quality Involvement: Engaged with vendors to align on quality expectations, review their FMEAs, and ensure upstream risk controls were implemented for raw materials, seals, and precision tubes.

Production Part Approval Process (PPAP)

I led and supported the successful submission and approval of PPAP packages for both domestic and export customers, particularly Tier 1 automotive and off-highway OEMs. My tasks included:

Preparation and submission of Level 3 PPAP documentation, including:

• Process Flow Diagram

• PFMEA

• Control Plan

• Dimensional Results

• Material Certifications

• Initial Process Study (Cp/Cpk)

• Appearance Approval Report

• Part Submission Warrant (PSW)

• Conducted Gage R&R studies and MSA (Measurement System Analysis) to ensure gage accuracy and repeatability for bore diameter, piston rod straightness, and weld penetration depth.

• Performed First Article Inspections (FAI) and linked outputs to PPAP requirements.

• Coordinated with customers for on-site audits and PPAP validation.

This process ensured that production lines were capable of consistently producing parts that met customer requirements, and greatly improved our first-time-right performance in audits.

Statistical Quality Control and Six Sigma Application

Statistical rigor was central to my work. I leveraged SPC (Statistical Process Control) and Six Sigma tools to monitor and improve machining and assembly processes.

Developed and maintained control charts (X-bar, R) for honing, turning, and welding processes, identifying trends and implementing corrective actions proactively.

Calculated process capability indices (Cp, Cpk) to validate process stability and reduce non-conformities.

Led a Six Sigma Green Belt project focused on reducing internal rework in cylinder assembly due to seal leakage and improper torque settings. The project followed the DMAIC methodology:

• Define: Identified high rework in pressure testing phase

• Measure: Collected baseline data on failure modes

• Analyze: Used Pareto analysis, Fishbone diagram, and 5 Why techniques

• Improve: Implemented better torque tools, seal handling SOPs, and training

• Control: Established monitoring KPIs and visual standards on the line

• Outcome: 47% reduction in rework incidents and improved overall equipment effectiveness (OEE) by 12%.

Internal Auditing and ISO 9001:2015 Compliance

• I was a trained internal auditor for ISO 9001:2015 and played an active role in maintaining our QMS through:

• Periodic process audits, ensuring compliance with documented procedures and identifying opportunities for improvement.

• Participating in management review meetings, preparing audit findings, non-conformity trends, and KPI dashboards.

• Supporting the external ISO certification audit process and successfully closing all audit observations through structured Corrective and Preventive Actions (CAPA).

• Driving document control, ensuring SOPs, quality manuals, and work instructions were updated and version-controlled.

• Customer Interface and Complaint Management

• I served as a key quality contact for OEM clients, particularly during:

• Customer complaint investigations (8D problem-solving)

• Warranty return analysis and root cause verification

• Defining and agreeing on containment actions and long-term corrective measures

• Conducting Gemba walks and joint inspections with supplier quality teams from client organizations

I gained significant experience in cross-functional communication, stakeholder management, and real-time decision-making to meet both customer expectations and internal quality goals.

• Inspection Methods and Metrology

• Proficient in the use and calibration of various precision inspection tools, including:

• Bore and height gauges

• Surface finish testers

• Coordinate Measuring Machines (CMM)

• Air gauges and electronic dial indicators

• Weld testing instruments (visual, dye penetrant)

  
  

I optimized sampling plans based on part complexity, risk level, and process capability, ensuring inspection resources were efficiently allocated and non-value-added activities were minimized.

Skills and Tools Used

• Quality Systems: ISO 9001, APQP, PPAP, FMEA, MSA, SPC, CAPA

• Statistical Tools: Control Charts, Pareto, Cp/Cpk, Histogram, Run Charts

• Problem-Solving: 8D, 5 Whys, Fishbone Analysis

• Software: Minitab, MS Excel (Advanced), SAP QMS, ERP systems

• Inspection Tools: CMM, height gauge, micrometer, digital indicators

Conclusion

My three years as a Quality Engineer in a hydraulic cylinder manufacturing setup gave me deep operational insight into precision manufacturing and process control. It was an environment where quality was critical not just for compliance, but for safety, reliability, and customer retention.

Through my work in APQP, PPAP, ISO systems, and Six Sigma, I developed the ability to not only detect and fix problems but to build quality into processes, design for manufacturability, and reduce variation at the source. These capabilities continue to define my approach to quality engineering in every new challenge I take on.