ZULFIKRI BIN YACOB CV (Curriculum Vitae)

SENIOR PROCESS QUALITY ENGINEER | MANUFACTURING ENGINEER | PRODUCTION ENGINEER

Result-driven Senior Process Quality Engineer with 11+ years of experience in pouch, cylindrical, EV battery manufacturing and quality engineering with excel in fast-paced environments and thrive under pressure. Proven record of reducing defect by 68%, improving process efficiency, and leading cross-functional team to implement SPC, MSA, CP and DMAIC methodologies. Skilled in root cause analysis, continuous improvement, data-driven problem solving (8D, 5Why, Fishbone, CAPA, PDCA) to optimize production and ensure compliance with ISO quality standard. A proven expert in orchestrating complex projects from conception to completion, with a relentless focus on optimizing resources, streamlining processes, and ensuring the timely, cost-effective delivery of critical cylindrical battery manufacturing sector.

1. ZUL FIKRI YA’COB
Seremban, Negeri Sembilan • [phone] • [phone]
[email protected] • https://www.linkedin.com/in/zul-fikri-ya-cob

SENIOR PROCESS QUALITY ENGINEER | MANUFACTURING ENGINEER | PRODUCTION ENGINEER

Result-driven Senior Process Quality Engineer with 11+ years of experience in pouch, cylindrical, EV battery
manufacturing and quality engineering with excel in fast-paced environments and thrive under pressure.
Proven record of reducing defect by 68%, improving process efficiency, and leading cross-functional team to
implement SPC, MSA, CP and DMAIC methodologies. Skilled in root cause analysis, continuous
improvement, data-driven problem solving (8D, 5Why, Fishbone, CAPA, PDCA) to optimize production and
ensure compliance with ISO quality standard. A proven expert in orchestrating complex projects from
conception to completion, with a relentless focus on optimizing resources, streamlining processes, and
ensuring the timely, cost-effective delivery of critical cylindrical battery manufacturing sector.


CORE COMPETENCIES AND ACHIEVEMENTS

● Production and Process Improvement: identified and prioritized key processes for continuous
improvement. Implemented activities that led to a 68% reduction in short resistance defects and a
significant decrease in overall defect rates. Utilized DMAIC methodology to drive quality and productivity
improvements.
● Quality Management and Auditing: Conducted internal and product audits to ensure adherence to
quality. Managed all audit findings and implemented corrective actions, resulting in improved quality and
compliance. Received recognition for reducing slip-through defects and achieving quality standards that
earned awards and incentives.
● CAD Software Proficiency: Regularly used AutoCAD and SolidWorks to update and review mechanical
designs, ensuring compliance with industry standards. This proficiency led to a 20% reduction in design
errors and enhanced machine reliability at Samsung SDI Energy Malaysia.
● New Cylindrical Battery line setup: Participated in the setup and qualification of new battery production
lines, including preparation and installation at both Samsung SDI Energy Malaysia and Tenpower
Malaysia. Coordinated with engineering teams to ensure quality requirements were met, leading to
successful new line setups and effective production processes.
● Quality System and Equipment Setup: Expertise in issuing quality anomaly reports, initiating quality
improvement projects, and conducting closed-loop management using DingTalk application (Tenpower
Malaysia quality management system). Proficient in using measurement tools such CT scan Royma,
Metrohm moisture trace, electronic Balance scale, scale projector, MAHR thickness gauge and high-
capacity Measuring Microscope.
● Process Improvement Tools: Proficiency in foundational techniques used to identify, analyze, and solve
quality problems such as Cause-and-Effect Diagram (Fishbone Diagram), Check Sheet, Control Chart (MSA
& SPC), Histogram, Pareto Chart, Scatter Diagram, and also have expertise in problem-solving
methodologies 8D, 5Why.
● Analytical Skills: Utilized Root Cause Analysis (RCA) to address and reduce production downtime,
ensuring continuous and effective operation.
● Project Management and Coordination: Led and coordinated various projects, including the setup of
new battery lines and quality improvement tasks. Managed procurement, technical assessments, and
project execution, which resulted in high client satisfaction and successful project completion
● Defect Reduction and Quality Enhancement: Achieved significant reductions in tab bend defects and
winding process defects. Developed and implemented new standard operating procedures (SOPs) that
improved quality and productivity, and received recognition for these achievements.
● Environmental and Waste Management: Established water treatment programs using granular
activated carbon filters. This initiative led to a 40% reduction in water usage for cleaning latex gloves,
demonstrating a commitment to environmental sustainability and cost reduction.

2. PROFESSIONAL EXPERIENCE

Senior Process Quality Engineer | PQC Team leader | Tenpower Malaysia | 2025 – Present

The phase of setup new cylindrical battery manufacturing line for slitting and winding process.
 Participated in setup new quality section at fourth plant of Tenpower factory by collaboration with HQ
mentor, accomplished finish setup measuring tools in targeted duration.
 Led the in-process quality inspector in learning the new quality measuring tool such as CT scan Royma to
measure the alignment anode and cathode, Metrohm moisture trace to measure moisture electrode
after high-temp process, and high-capacity Measuring Microscope to measure the slitting burr.
 Participate in trial runs (pilot production) and introduction of new processes, products, and equipment
by complete process quality validation and output reports by providing the first pass yield and final yield
rate data trend (FPY).
 Be responsible for the daily management, task assignment, performance evaluation, and skill training of
the process quality team (e.g., IPQC, PQC).
 Collaborate with SQE to analyze and provide feedback on supplier incoming material quality issues,
driving supplier quality improvement.
 Participate in the investigation and analysis of customer complaints, ensuring timely and accurate
provision of root cause analysis and corrective action reports.
 Manage the Non-Conforming Product (NG) handling process, including isolation, review, disposition, and
traceability to prevent unintended use.

In accordance with the requirements of the Quality Anomaly Management Regulations, responsible for:
 Issuing quality anomaly reports, initiating quality improvement projects, and conducting closed-loop
management.
 Collaboration with other team to promote the cause analysis of quality anomalies and the
implementation of improvement work.
 Coordinate the development of the work section control plan (CP) management and compiling the
process inspection item, conducting training, and supervising the implementation by IPQC (In-Process
Quality Control) personnel.
 Identifying and selecting appropriate inspection equipment, establishing the operation line inspection
and maintenance specifications for testing equipment, and supervising their implementation.
 Supervised the progression quality inspection training of IPQC (In-Process Quality Control) personnel and
assessing their competence, resulting in reduction of misjudgment in product quality inspection.
 Initiated the effectiveness of the process inspection and measurement system, analyzing deviation
points, implementing improvement measures, and tracking their effectiveness.

Achievement:
 Develop quality inspection method learning material for IPQC and proven to reducing inspection error
by 20% and shorten duration of leaning progress by 50%.
 Using Measurement System Analysis (MSA) to identify the source of quality inspection data variation
among IPQC, thus improve measurement accuracy, reduce inspection errors by 35%.
 Implement electrode thickness check sheet data verification for electrode pairing progress, this method
proven to reduce core diameter issue for 23%.
 Establish the AB chuck gripper material audit to determine the material life span, this activity help reduce
slip thru issue of reform and diameter abnormal.
 Implement the CCD vision bypass verification check sheet to reduce the human error in specification data
changing at machine panel.

Senior Manufacturing Quality Engineer | Samsung SDI Energy Malaysia | 2014 – 2025

 Responsibility includes identifying and prioritizing key processes for continuous improvement in quality,
productivity, and cost reduction. This involves troubleshooting non-conformance issues in
polymer/pouch battery production, managing quality and productivity improvement projects using
DMAIC methodology, and overseeing internal and product audits.
 Achievements include reducing short resistance defects by 68%, improving productivity, and winning top
honors in Samsung's internal competitions.

3.  Developed new SOPs that enhanced both quality and productivity, and received recognition for
significant contributions to quality improvement.
 Won 1st rank the BOB (best of the best) competition between Samsung battery plant as best defect rate,
production efficiency and PO target (purchase order) achieve.

The phase of setup new cylindrical EV battery manufacturing line for winding process.
 Participated in setting up new EV battery production lines and collaborated with quality and engineering
teams to ensure high production standards.
 Managed quality improvement tasks, including periodic internal audits and machine efficiency analyses.
 Achievements include reducing tab bend defects by 38%, sustaining improvements in winding defect
rates, and designing a cost-reducing product chuck transfer unit.
 Design new product chuck transfer unit by reduce the gripper material thickness for 20% and implement
it inside production line for material cost reduction activity.
 Responsible to conduct quality improvement activity in term of 4M’s operation management by
categories issues impacting operations into Materials, Methods, Machines, or Manpower.
 Responsible to troubleshoot non-conformance product to regain and sustain the 21700-model battery
production manufacturing quality.
 Receiving award 3rd rank for Samsung SDIEM SGA (small group activity) competition for winding
technology department.

Blow Molding Technician | Nur Kasturi Sdn Bhd | 2013 – 2014

 Assisted engineer in managing and supervising the process of blow molding in order to improve the
quality and quantity target of plastic bottle products.
 Best achievement: Refined and improved existing quality inspection method and procedure of bottle
leaking defect, resulting in reduced material and labor costs totaling 30% percent annually via increased
production efficiency and rates (PO).

Industrial Trainee | FWK Sdn Bhd | 2011 – 2012

 Identify opportunities for improving the quality of plastic bottles production, and recommend changes
to the Production Engineering Manager as needed.
 Best achievement: Played an important role in the production team to establish the water treatment
programs from latex waste water by using granular activator carbon (GAC) filter. Resulting in reducing
using plain water for clean latex glove odor at 40 % percent.


EDUCATION AND TRAINING

University Malaysia Perlis (UNIMAP)
Bachelor in Material Engineering & Diploma in Metallurgical Engineering

Advanced Measuring QC Tool
CT scan Royma, Metrohm moisture trace, electronic Balance scale, scale projector, MAHR thickness gauge
and high-capacity Measuring Microscope.

Quality Control Tools
Cause and Effect Diagram, FMEA, PDCA, Pareto Chart, PDPC, RCA, Gemba Walk, Relation Diagram, 8D,
5Why, CAPA

Quality Analyzing Tool
SPC (Statistical Process Control), MSA (Measurement System Analysis) and CP (control plan)

REFERENCES
Noor Izwan Rasli
PQC Section Leader, Tenpower Malaysia
Contact no: [phone]
E-mail: [email protected]
Nik Amirul Asyraaf
Assembly PQE, Tenpower Malaysia
Contact no: [phone]
E-mail: [email protected]