Eduardo Melo

Managed new product development from planning to PPAP approval, ensuring compliance with customer requirements and IATF 16949. Led APQP Core Tools (PFMEA, Control Plans, SPC, MSA), product and process validation, supplier qualification, audits, and root cause analysis (CAPA, 8D, 5 Whys). Conducted feasibility studies, led Technical Reviews, supported business growth (+27%, USD 4M+), improved contribution margin by 17%, and optimized manufacturing processes for serial production.

Planned and conducted internal, process, and supplier audits to support ISO 9001 compliance and continuous improvement. Implemented standardized procedures, work instructions, Quality Control Plans, PPAP, Control Plans, FMEA, SPC, and MSA. Applied Poka-Yoke and led root cause analysis using 8D, 5 Whys, and Ishikawa to drive corrective actions. Reduced manufacturing scrap by 4.3%, generating annual savings of approximately USD 140,000.

Led cross-functional teams and delivered projects on schedule, improving the success rate by 62%. Managed APQP (PPAP) documentation. Conducted weekly meetings to keep project activities aligned. Met regularly with clients to coordinate deadlines and technical requirements. Performed critical post-development analyses. Oversaw the development of 16 new projects in 15 months, achieving a 100% on-time delivery rate.

Supervised investment casting product development for a Swiss multinational, ensuring compliance with technical specifications. Prepared initial sample approval documentation, developed and qualified machining suppliers, and achieved 100% compliance in international approval audits. Presented project results in Switzerland and provided technical consulting in the Czech Republic to resolve manufacturing challenges, strengthen supplier readiness, and support product approval.

Led automotive parts development projects using APQP for customers including GM, VW, Fiat, and ABB. Performed feasibility studies and technical reviews for new product requirements and specifications. Coordinated meetings with domestic and international customers to align project schedules and technical expectations. Worked closely with multidisciplinary teams to ensure project execution and resource availability. Successfully achieved PPAP approvals for complex automotive and aerospace components.

Implemented quality control systems that reduced the rejection rate from 12% to 4%. Managed non-conformity reports and 8D action plans. Addressed customer complaints by identifying root causes and applying corrective actions, which lowered recurrence by 86%. Made regular technical visits to automotive clients to confirm product compliance. Conducted internal and external audits to improve supplier quality indicators.