Senior Quality Consultant – Railway, Automotive & Aerospace

Integrated quality teams at major railway manufacturers (Alstom) and automotive manufacturers (Lucid Motors) as senior consultant, supervising part inspection and coordinating international supply flows between Europe and Asia.

• Conducted First Article Inspections (FAI) on injection-molded plastic, composite, and metal interior parts (trim panels, seat components) for railway rolling stock, emphasizing aesthetic compliance (surface finish, color, grain, dimensional tolerances).
• Implemented quality walls with suppliers to contain non-conformities (visual defects, dimensional deviations) and prevent defect circulation in production.
• Managed NCRs and drove supplier corrective action plans (8D) with emphasis on visual defects and process stability.
• Coordinated international material flows between Italy and Japan, ensuring delivery of critical components.
• Served as interface between suppliers, engineering, and production teams to align quality requirements.
• Performed quality control and inspection of interior parts for Lucid Motors at supplier site Persico Group.
• Ensured supply chain continuity for Taiwan project, preventing production stoppages.
• Improved reliability of transcontinental deliveries.
• Reduced communication gaps between intercontinental teams.
• Supported integration of Famiglia Artigiana as harness supplier for Iveco.
• Guaranteed delivery of compliant parts to Lucid Motors for new projects.
• Technical environment: FAI inspection, visual quality control, dimensional tolerances, NCR management, 8D, international logistics coordination.

Joined quality department (10 people) of tier 2 company specialized in injection molding and assembly of plastic parts (oil reservoirs, fuel tank caps) for automotive industry.

• Drove quality management for customer, project, and supplier for injection-molded plastic components.
• Designed and implemented QC/QA processes focusing on aesthetic control (surface defects, weld lines, sink marks, color consistency).
• Developed FMEAs, managed PPAP activities and product/process validation (APQP) for new plastic parts.
• Conducted root cause analysis and drove corrective actions following non-conformities.
• Supervised IATF 16949 and ISO 14001 quality system monitoring (management review, KPIs).
• Implemented continuous improvement processes: 5S, Kanban, SMED, Hoshin.
• Reduced non-quality cost from 50k€ to 5k€.
• Decreased customer complaints from 45 to 5 per year.
• Achieved IATF 16949 and ISO 14001 site certification.
• Qualified new suppliers for plastic injection components.
• Technical environment: Plastic injection, molding, aesthetic control, FMEA, PPAP, APQP, IATF 16949, ISO 14001, 5S, Kanban, SMED, Hoshin.

Assumed full P&L responsibility as director of automotive wire harness manufacturing plant, leading 200+ person team.

• Reorganized plant layout and optimized production flows, increasing productivity from 60% to 85%.
• Managed complete supply chain: procurement, inventory management, supplier purchase order launch, logistics.
• Increased EBITA from 5% to 12% over 3 years.
• Reduced delivery lead time by 30% and improved production space utilization by 25%.
• Technical environment: Wire harnesses, flow optimization, P&L management, inventory management, procurement, logistics.

Drove quality for tier 2 company specialized in automotive interior trim (seats, door panels, complete upholstery), supervising 20-person team distributed between Italy and Tunisia.

• Managed finished product quality inspection with emphasis on aesthetic and appearance criteria.
• Defined and negotiated aesthetic acceptance criteria for leather, fabric, stitching, and final assembly.
• Implemented quality walls and conducted customer audits.
• Led ISO/TS 16949 standard implementation across both plants (Italy and Tunisia).
• Conducted Run@Rate processes for new projects (APQP).
• Defined and implemented control plans for seats and door panels.
• Reduced customer PPM from 1700 to 100 ppm.
• Achieved ISO/TS 16949 certification.
• Successfully launched new interior projects for Audi and Ford.
• Technical environment: Automotive interiors, seats, door panels, upholstery, aesthetic control, leather, fabric, APQP, PPAP, ISO/TS 16949.

Joined quality department (20 people) at Lear Corporation, tier 1 supplier for PSA, specialized in automotive wire harness manufacturing.

• Supervised quality department management.
• Conducted process audits and monitored associated action plans.
• Monitored quality controls at each workstation in accordance with control plans.
• Managed customer complaints (8D).
• Tracked quality key performance indicators (KPIs).
• Led daily quality meetings (QRQC).
• Technical environment: Automotive wire harnesses, process audits, quality control, 8D, QRQC, KPIs.

Joined quality team at tier 1 Cotrel (Fiat and Iveco clients) specialized in design and manufacturing of conventional and parabolic leaf springs for all vehicle types (heavy machinery and automotive sector).

• Served as customer contact for complaints and quality aspects.
• Managed laboratory activities and product qualification testing.
• Monitored process parameters (SPC, MSA, capability analysis).
• Conducted daily manufacturing meetings.
• Drove problem resolution for internal and external complaints.
• Conducted internal audits of processes and products.
• Supported ISO/TS and ISO 14001 certification implementation.
• Supported advanced quality projects and PPAP preparation: development and execution of quality plans, product qualification (material and product characteristic controls), process qualification (statistical control, audits).
• Technical environment: Leaf springs, quality laboratory, SPC, MSA, capability analysis, PPAP, ISO/TS, ISO 14001.