Mohsen Khalajzadeh

Results-driven Quality Assurance and Continuous Improvement Leader with 20+ years of manufacturing experience across metal fabrication, welding, machining, HVAC, and automotive production environments. Proven track record of building Quality Management Systems from the ground up, leading Lean transformation initiatives, and driving measurable operational improvements in complex industrial operations. ISO 9001:2015 Lead Auditor and Lean Manufacturing professional with expertise in SPC, FMEA, RCA, CAPA, Value Stream Mapping, KPI systems, and ERP implementation. Recognized for reducing scrap and rework by 40%, achieving 98%+ On-Time Delivery, and maintaining zero major nonconformances across third-party audits over a 10-year period. Hands-on operational leader with extensive experience collaborating across production, supply chain, quality, engineering, and safety teams to improve performance, standardize processes, strengthen accountability, and build sustainable continuous improvement cultures.

• Lean Manufacturing
• Microsoft Excel

1. Independent QA & CI Consultant

   Self-Employed

   nov. 2024 to Aujourd’hui

   Calgary, AB

   Operational Excellence & Manufacturing • Supporting Alberta manufacturing companies with operational excellence initiatives focused on Lean transformation, ISO systems, production flow optimization, and manufacturing scalability • Providing ISO 9001:2015 Quality Management System design, audit readiness, and certification consulting services • Conducting Value Stream Mapping, production flow assessments, and Continuous Improvement roadmap development • Advising manufacturing clients on NCR/CAR systems, Visual SOPs, internal audit programs, and process standardization

2. Manufacturing Engineering Lead / Senior CI Consultant

   Scott Springfield

   févr. 2023 to oct. 2024

   Calgary, AB

   Acquired by Modine; 500+ employees multiple plants • Led multi-plant Value Stream Mapping and facility layout redesign projects across metal fabrication and HVAC manufacturing operations • Redesigned material flow patterns and production workflows, achieving a 20% improvement in operational efficiency across multiple production areas • Collaborated with Operations, Supply Chain, and QA leadership teams to implement and sustain Lean-based operational improvements • Identified and eliminated key production bottlenecks in fabrication and assembly workflows through structured root cause analysis and process redesign • Supported production scheduling alignment and workflow optimization initiatives to improve operational flow and delivery performance

3. QA Manager & Continuous Improvement Manager

   Luff Industries

   janv. 2013 to janv. 2023

   Calgary, AB

   Metal Fabrication & Industrial Manufacturing; 200+ employees multiple plants • Quality Systems Leadership • Built the company’s Quality Assurance and Quality Control function from the ground up, implementing NCR/CAR/CAPA systems, inspection procedures, Visual SOPs, and a complete ISO 9001:2015-compliant QMS • Successfully upgraded and maintained ISO certification with zero major nonconformances across all scheduled third-party audits over a 10-year period • Conducted internal audits, coordinated external audits, and managed corrective action processes to ensure continuous compliance and operational accountability • Implemented SPC and process capability studies (Cp/Cpk) across welding, machining, and fabrication operations to improve product quality and process consistency • Led FMEA, RCA, and corrective action initiatives to identify and permanently eliminate recurring quality failures • Continuous Improvement & Manufacturing Operations • Led Lean transformation initiatives across welding, machining, fabrication, and assembly departments through GEMBA systems, Value Stream Mapping, and TAKT-based workflow redesign • Reduced scrap and rework by 40% through Lean Manufacturing and Six Sigma initiatives, generating significant operational cost savings • Improved cycle time by 15% through manufacturing flow redesign and process optimization initiatives • Achieved 98%+ On-Time Delivery through production scheduling improvements, workflow coordination, and material flow optimization across multiple production lines • Supported day-to-day cross-functional manufacturing operations involving fabrication, machining, welding, and assembly teams • Leadership, Safety & Systems • Managed and mentored supervisors and production personnel across multiple manufacturing departments, fostering a culture of accountability, engagement, and continuous improvement • Developed and delivered training programs for welders, machinists, supervisors, and management teams to strengthen process consistency and quality ownership • Reduced safety incidents by 40% through systematic job hazard assessments, proactive risk mitigation, and collaborative safety culture development • Designed and implemented company-wide KPI dashboards providing leadership with real-time visibility into quality, production, and OTD performance metrics • Served as Project Manager for the end-to-end Epicor ERP implementation, including production scheduling engine launch and operational integration • Built the Quality Assurance and Quality Control function — designing and implementing NCR/CAR systems, Visual SOPs, inspection procedures, and a full QMS aligned to ISO 9001:2015 • Successfully upgraded the company's ISO certification and maintained zero major nonconformances across all scheduled third-party external audits over a 10-year period • Conducted scheduled internal audits and managed all external audit relationships — preparing teams, coordinating documentation, and closing findings within defined timelines • Implemented SPC and process capability studies (Cp/Cpk) across welding, machining, and fabrication processes — driving measurable improvements in product quality and consistency • Deployed FMEA, RCA, and structured corrective action processes to identify and permanently eliminate recurring quality failures

4. Operations & Manufacturing Engineering Manager

   AzinKhodro Automotive

   janv. 2000 to janv. 2012

   Iran

   Large-scale Automotive Manufacturing; 3,000+ employees multiple plants • Managed production engineering and continuous improvement initiatives across a large-scale automotive manufacturing operation over a 12-year tenure • Led production scheduling, workforce coordination, and shop-floor operations across multiple manufacturing departments • Implemented SPC and capability studies (Cp/Cpk) to improve product quality and process consistency across high-volume production environments • Developed and deployed Value Stream Mapping projects, standard work systems, and flow optimization initiatives to establish Lean manufacturing practices • Conducted systematic operational and safety risk assessments to proactively identify and eliminate production issues

5. Mechanical Design Engineer

   Micron Machinery

   janv. 1998 to janv. 2000

   Iran

   Fully Automatic Pasta Line; 80+ employees single plant • Designed mechanical systems and HVAC components for fully automated industrial production lines • Led field installation, commissioning, maintenance, and troubleshooting activities to ensure operational reliability and equipment uptime

1. Azad University

   Bachelor of Science (B.Sc.), Mechanical Engineering

2. Arak Technical College

   Associate Degree, Welding Technology

• ISO 9001:2015 Lead Auditor

• Lean Gold Certificate (Black Belt Equivalent)

• Project Management Certificate

• Job Risk Assessment & Fall Protection Certification