Quality Reliability Engineer

Resume

Shaique M. Ali Tel. Cell: 734-

***-****

***** ********* **., ******, ** 48188 Email:

acf14r@r.postjobfree.com

Professional Highlights:

I am an analytical and performance-driven engineering professional with extensive experience in

Quality and Reliability assurance. Diversified experience in multi tasking environment with data driven

approach in extreme workload conditions. The Advanced Quality Planning (AQP) and Reliability

planning has been areas of interest. In recent past I have dealt into Casting, Machining, Stamping. Tube

Bending, Welding, Heat Treating, Injection Molding and various manufacturing assembly operations.

My post graduate experience has been in the process industry/oil and gas.

Strengths:

• Six Sigma Black Belt & Problem solving • Advanced Product Quality Planning tools (APQP)

• Supplier Quality Assurance • Supply base ISO 9001, 14001 and 18001 audits

• • Change Management Coordination

Lean Manufacturing Tools • Design Verification & Production Validation Testing

• DFMEA/ PFD / P&ID/ PFMEA • Reliability Testing, MTTF/MTBF/Weibull

• analysis

Reliability Testing, MTTF, MTBF

Trainings:

QMS (ISO 9001), API Spec. Q1, Process Piping Design (ASME/ANSI 36.10, 36.19, 31.3, 16.9, 16.5)

Risk Assessment, (FMEA), Quality Planning (APQP), Internal Auditing.

Education:

(Win. 00, Sum.94)

MS: Manufacturing Engineering from Wayne state university, Detroit, MI, USA.

BS: Chemical Engineering from NED University of Engineering & Technology, Karachi, Pakistan.

Supplier Quality Engineer, Ford Motor Company, Detroit, MI, USA.

World Largest Automaker in the world.

(Feb. 2008 – To date)

Engage in Program Management, Advanced Quality Planning and coordination activities on new

program launches.

Coordinate engineering changes. Approve agent of ‘supplier requests for engineering changes’.

• Sourcing, developing, auditing component supply base. Led Production part approvals (PPAP)

with special focus on SPC, DFMEA, PFMEA, Process flow diagram (PFD) and Control plans.

• Coordinate resolving parts quality issues during development / launch / production of casting,

machining, stamping, injection molding and bending processes of a vast supply base.

• Suppliers’ audits of Ford’s Quality Q1/ISO 9001. Managed suppliers for new programs and

current production issues.

• Implement and execute ISO 9001, 14001 and 18001 systems on selected supply base. Review

and audit Quality Manual, Procedures, Forms and Work Instructions of integrated management systems.

Project Quality Engineer, Valeo Compressors, Detroit, MI., USA

Manufacturer of Automotive AC Compressors

(Aug. 05 – Sep. 07)

• Launched multiple programs successfully with Ford and Chrysler. Led advanced quality team (AQP)

meetings to identify program risks/opportunities for production part approval (PPAP). Special Focus on PFD,

FMEAs and Control Plan.

• Audit and PPAP Machining, Casting and Clutch suppliers. Developed safe launch procedures for all

supply bases.

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Quality Reliability Engineer

Resume

• Developed and launched Engineering change mangement system/database for a proper/timely

communication.

• Coordinated customer warranty tear down and data analysis meetings and hence led warranty projects.

Reliability Engineer, Ford Motor Company, Detroit, MI., USA

Climate control system - Refrigeration, Heater, Electrical and Air handling subsystem

(Mar. 04 - Aug. 05)

• Warranty data and tear down analysis reviews with suppliers for robust design and new model

development.

• Led design risk/failure assessments through Design FMEA. Design reliability assessment via design

verification testing and hence estimations of Minimum life, Mean life (MTBF) and B5/B10 lives by using

Weibull++ software.

• Extensive use of Block and functional diagram, Parameter-diagram, Reliability Checklist and Fault Tree

Analysis.

• Performed high mileage projects. Established cycles to miles correlation for test bogey test up.

Reliability Engineer, Visteon Corporation, Detroit, MI, USA

Chassis systems - Axle driveline, Brakes, Exhaust systems

(Mar. 00 - Jan 04)

• Launched multiple programs with reliability assessment of multiple Chassis components.

• Led multiple teams to review warranty data and test results with Weibull plots for failure analysis and life

estimations.

• Led warranty projects on Drive Shaft, Catalytic Converter noise, Axle Cover leak and Wheel & Pinion

Shaft Seal leak.

• Led Drive Shaft U-Joint B10 life reliability improvement project, Drive Shaft Slip Yoke material change

project, Stabilizer bar link & Mounts project for noise reduction and lateral movement. Support Six-Sigma

project on Rear Brakes noise issue.

• Lead DOE projects on suspension coil spring for side force reduction, Driveshaft friction weld fatigue life

improvement.

• Performed Weibull (failure/reliability) analysis, cycles/miles correlation, reliability test plans, S/N curve for

test target.

Reliability & Safety Engineer, Gatron Polyester, Karachi, Pakistan

A large producer of Polyester Chips and Yarn

(Jan. 95 – Mar. 97)

• Driven asset care and Total Productive Maintenance strategies, Led maintenance planning and procedure

updates. Facilitated root-cause failure analysis (RFCA) events. Led clean, tag, & inspect exercises.

• Reviewed and analyzed PM data of Thermal Scanning, Ultrasonic, Vib. Monitoring for preventative

maintenance actions.

• Reviewed engineering specs of process equipment like Drier, Crystallizer, Extruder, Manifold and polymer

pumps for reliability capability. Reviewed and managed contractor proposals for compliance of reliability

program. Developed and implemented Reliability plan for high speed winding system including high speed

winders.

• Led FMEA with Maintenance, Engineering and Environmental teams to ensure best maintenance practices are

employed.

• Established HSE management system. Developed safety signs, alerts, procedures and operators trainings.

• Developed the required documentation, operational checks and reports for the Safety, Environment and Health.

• Monitored and Managed controllers on coordinating and executing Safety, Environment and health audits.

• Investigated the root cause of HSE complaints by staff, customers, clients and contractors. Reported results

into managers.

• Ensured emergency response exercises and drills are conducted for the highest level of preparedness in any

emergency.

HVAC Engineer, A.A. Consultants, Karachi, Pakistan

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Quality Reliability Engineer

Resume

(Sep. 93 – Dec. 94)

• Calculated heat load with the help of the manuals as per the norms of the organization.

• Coordinated with the clients and consultants and provided good communication channels on all the

engineering issues.

• Monitored all the electrical and plumbing process of the project and ensured that the work was done smoothly.

• Provided firefighting facilities in the location as per the requirement.

• Coordinated with the AC and Ducting Supervisor and resolved all technical problems in the facility.

• Developed Maintenance Plans for Blowers, Compressors, Chillers, Cooling Towers, Pumps, Motors and Ducts.

References can be provided upon request.

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