ZACHARIAH VARUGHESE

***** ********* **

Houston Tx 77433

214-***-****

acfq1h@r.postjobfree.com

OBJECTIVE:

Seeking experienced Sr Design Project Engineer position which can

utilize my experiences in oil and gas product design . New product

introduction, projects which are value added in product design.

Accomplishments:

Improved process by studying the process, and implementing changes which

reduced cycle time by 50%.

Successfully executed projects from the drawing inception to

implementation.

Enhanced problem-solving skills, to resolve mechanical/electrical issues.

Follow up with technical reports.

Excellent communication and written skills. Interface with various

functional groups. Multitasking and managing projects through completion.

Capital projects 300-500k ..

Used Auto CAD/Solid works 3D, CatiaV5, to improve mechanical product

design, design layout, and development of tooling, jigs and fixtures. Use

of GD &T in drawings.

Continuous improvements in fabrication, machining, assembly,

documentation, and product design.

Lean six sigma project applications using tools like

5S,VSM,KAIZEN,DOE,Simulation,DFMEA,DFM,POKYYOKY

Saved $400,000.

Evaluating and resolving design for manufacturing problems in electro-

mechanical assemblies.

Project management of multiple projects,process drawings, evaluating

methods, process flow mapping,

estimating project times, production workforce utilization,maintain

project matrix and presentation.

Application of procedures in API,ASTM, ASME VIII, IX B 31.1,31.2.31.3

AWSd1.1,QS,ISO 9001-2000, standards..

EMPLOYMENT HISTORY:

Baker Hughes

Tx

Position: Sr Mechanical Project Engineer

2009- present

.

. Design and documentation of assembly drawings. Product design of MWD

/LWD,Completions oil tools,HPHT frac equipment for wireline and

drilling systems.

. Use of thermal analysis, FEA for product development. Detailed project

reviews, cost analysis. Analysis and modification of standard products

to suit the needs of customers.

. Worked on Prototyping, developing, Integrating, testing of Fracpoint

open hole completion packer system project.

. Developed project plans to completion,worked with other engineering

resources for completion of the projects. Prepare prototypes for

operational functional test.

. Apply standard documentation after approval,all records of test,

specification, and analysis.

. Applied DFM,DFMEA principles in reducing defects, and executing

projects towards completion. Analysis of field reliability reviews and

concurrent engineering for reliable product design.

.

Cameron Elastomer International

Katy, Houston

2008-2009

Position : Sr Mechanical Engineer

. Process Improvement in Elastomeric Composites, Seals, BOP product

manufacturing applying lean

Six sigma. Saved $50k /yr

. Developed work instructions for each work center/cell in elastomeric

manufacturing

process.

. Tooling design and equipment modifications. Machinery maintenance

. AFE and new machinery justification.

. Assist in implementing HSE.

. Root cause analysis and continuous improvement of process,

manufacturing methods

and equipment. Implement corrective action. Reduced scrap rate.

. Experience in injection molding, transfer molding, compression

molding, mixing, milling, material handling, testing in R&D

activities.

GE ENERGY(contract)

HOUSTON TX

2008-2008

Position: Product Engineer

. Prepare Engineering NPI presentations in support of the Engineering

Product Leaders.

. Drive action items to closure.

. Review standard Product Line change requests prior to their

submission.

. Present configuration changes of the standard product to the Product

Control Board/CCB/MRB at Tollgate Review meetings.

. Manage design changes to the standard configuration.

. Coordinate proposal requirements and manpower estimates.

. Work with the planner to update project status, create BOM in Oracle,

and develop risk mitigation plans.

. Communicate with key stakeholders including Manufacturing, Sourcing

and Engineering Management.

. Prepare recommendations, costs, benefits, for design improvements,

manufacturing process improvement implementation in a team

environment.

. Electrical /Mechanical fabrication, welding procedure, and assembly of

Gas Turbine Engines Package systems.

. Apply Six Sigma tools and processes.

Smith International

Houston,Tx.

2006- 2008

Position : Sr Mechanical Engineer

. Design and documentation of down hole drilling equipment, Drill Bits,

Fishing Tools,Various Packers and assembly.

. Initiating ECR'S,ECO Drawing Changes .BOM development,PD drawings.

. Coordinating with R&D group, maintaining oracle engineering BOM in

Oracle ERP system.

. Project justification, & implementation, maintaining time line for

projects, analyzing make or buy decisions.

. Fixture, and tooling design, product design, design layout, and

special projects handling. Installed Cells based on lean analysis.

. Analyze work force utilization and space for maximum efficiency and

improve productivity.

. Concurrent engineering to develop new products and ensuring

manufacturability is applicable to current design.

. Review existing and new design drawings for DFM.

. Familiarity with current API,ASMEVIII,IX codes and standards.

. Production and resource planning using PDM systems.

. Assist in HSE, and mitigate risk in design.

. Lean Manufacturing six sigma project analyses and implementations.

. Documenting Specification,Analysis, WPS, heat treatment, NDT and

assembly in product development..

. CNC programming,and coordinate drawing/program improvements as

needed.

. Coordinating with purchasing regarding material cost, and estimating

labor cost for product cost simulation.

. Protyping,Testing,Design reviews for NPI.

. Saved company $94,000/year in product design improvement

implementations.

Ingersol Rand/Atlas Copco

Garland, TX

2003-2005

Manufacturing/Industrial Engineer

. Manufacturing support. Product Design reviews.

. Application of Lean Manufacturing Principles. Saved $148k/yr by

efficiently executing continuous improvement projects.

. Modified layout for subassembly, coupled with time study, KAIZEN

events to improve productivity.

. Installed KANBAN system for all machining components and assembly.

. Designed jigs and fixtures for derricks, tooling drawings for

Oil&Gas,Mining, Caterpillar,Cummin Engines assembly, compressor

assembly, rig fabrication and assembly.

. Analyze work force utilization and space for maximum efficiency

and improve productivity.

. Work concurrently with engineering to develop new products and

ensuring manufacturability is applicable to current design.

Initiating ECN'S.

. Production and resource planning using PDM systems. Time study,

run rate and router development.

. Review existing and new drawings for Design for manufacturability.

. Created process sheets and work instructions for metal turning, CNC

programming edge cam/g-codes manual.

. Contact with sub contractors and suppliers for product specifications

and arrange for purchasing equipment, parts,material and evaluate

product according to specification and quality standard.

. Troubleshoot defects for product failures, conduct root cause analyses

and take corrective actions. Take steps for preventative actions.

. Assist in HSE and maintain a safe work environment.

. Selection of automated assembly equipment and installation. Write

operational procedures, and PM procedures. Prepare area for internal

lean and ISO audits.

. Familiarity with current API, ASME VIII,IX codes and standards.

Welding Procedure, WPS, heat treatment, NDT and assembly.

Education:

B.S IN MECHANICAL ENGINEERING

M.S. IN ENGINEERING TECHNOLOGY, UNIVERSITY OF NORTH TEXAS,

Green Belt Lean Six Sigma Trained/certification.

Hydraulic Technology Certified.

Professional Registration: Society of Manufacturing Engineers.

COMPUTER SKILLS:

Microsoft office, Word 6.0,Excel 7.0,Microsoft Project 4.1,Power

Point,SAP,ORACLE ERP

Proficient in AutoCAD 2000,2007, Proficient in Solid works 3.0,

CAD/CAM Edge/Gibbs CAM,Siemens PLM,CATIAV5,Visio,UNICAM SMT,Gerber

Viewer, CINCINATI MILICRON, CNC PROGRAMMING of MASAK SLT-50W,MASAK SLT-

450,QT-350,30, Anayak hmv 500 mill,G7L MILL, Integrex 300SY,SORALUCE CNC

MILL,DAEWOO 400,800 CNC PROGRAMMING and other 5-axis Mori lathes, MORI-

SEKI MT 5-AXIS,Mori sl-600,603,Milltronics Vert mill programming, Kuraki

lathe, Gun Drill, RAM EDM, Laser Drilling,Linc oln Electric Cladding

robotics, AMADA BRAKE press, Amada benders.

Salary :Requirement: negotiable

Contact this candidate