TIRLOCHAN S. SANDHU

***** ********** **.

Strongsville, OH 44136

Home: 440-***-**** Cell: 440-***-****

ab075t@r.postjobfree.com

Highly accomplished, results-driven, self-motivated mechanical engineer with twenty-eight years of experience in the areas of Leadership, Process Improvement, Lean Manufacturing and Quality Operating System. Have strong planning and organizational skills with ability to multi-task and work in a fast-paced environment.

KEY STRENGTHS

1. Certified Six Sigma Black Belt – Completed 15 projects with a total combined savings of over $12M

2. Certified Instructor for Manufacturing Green Belt training

3. Certified Internal Auditor – ISO-9001:2000 / TS-16949

4. Certified Manufacturing Engineer (Casting & Molding) – Society of Manufacturing Engineers

5. Excellent knowledge and understanding of Quality Operating System tools - PFMEA, Process Control Plans,

Gage R&R, SPC, APQP, PPAP, 8D Problem solving, Error-Proofing and Capability studies.

1. International Experience (China) - Led team of JMC Engineers and completed assessment of cylinder block casting manufacturing operations and quality operating system. Organized, conducted and implemented results of Design of Experiments, resulted in about 20% scrap reduction. Provided coaching for Advanced Product Quality Planning (APQP) and ISO9000 audit requirements.

WORK EXPERIENCE

Senior Manufacturing Engineer

Ford Motor Company, Cleveland Engine Plants, OH

January 2004 to

Supervised and maintained overall Quality Operating System for two engine plants including launch of three new programs and coordination of various activities with the Corporate Quality Office.

1. Organized and conducted quality internal audits, reviewed findings and follow-up on closure verifications. Engine Plant 1 achieved highest rating during second party audit of Quality Operating System in 2005.

2. Developed and implemented local quality procedures to ensure compliance with corporate requirements.

3. Coached manufacturing teams with focus on launch readiness in the areas of QOS compliance, part of APQP. Conducted launch readiness assessment audits of various departments with closure follow-ups.

4. Leadplant representative for QS9000, ISO9001:2000 and Launch Readiness Assessment Audits.

5. Provide coaching for PPAP requirements during the launch of 3.0L, 3.5L and 3.7L engine programs.

6. Managed daily operations of Contamination Laboratory and Gage Management facilities.

7. Coached and supervised five quality coordinators involved in implementing and maintaining QOS activities.

8. Member of the PTO Quality office Cross-Functional team, developed and implemented Manage-the-Change

process for all Ford Powertrain Plants.

Senior Manufacturing Engineer

Ford Motor Company, Cleveland Aluminum Casting Plant, OH

November 2001 – December 2003

Supervised manufacturing process and quality operating system related to cylinder block casting. Provided technical expertise to resolve quality and productivity issues, resulted in significant manufacturing cost reduction.

1. In-Plant scrap improved by 40%, customer scrap improved by 97%, resulted in annual savings of over $4M.

2. Implemented and maintained overall Quality Operating System for the plant. Conducted internal audits and acted as leadplant representative during QS9000 and ISO9001:2000 audits.

3. Mentored, taught and coached engineers in the methodology of Six Sigma for their certification requirements.

4. Tracked and monitored black belt projects to successful completion to ensure meeting objectives.

5. Conducted Six Sigma Green Belt training for salary and hourly work force.

6. Provided technical guidance to core making equipment manufacturer to improve their initial machine design

based on my patent concept, resulted in 20% improvement in cycle time and productivity.

TIRLOCHAN S. SANDHU

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Senior Manufacturing Engineer

Ford Motor Company, Cleveland Casting Plant, OH

August 1984 – November 2001

Extensive experience as a Manufacturing and Quality Engineer in a large grey iron foundry, making cylinder blocks, heads and other components.

1. Full grade level promotion and assumed complete responsibilities for cylinder block manufacturing processes.

2. Supervised a team of five engineers, and acted as a mentor to summer interns.

3. Supervised manufacturing process and quality operating system requirements for 1.9L, 2.0L, 2.3L NVH, 2.5L, 3.0L, 4.9L, 5.0L and 7.5L cylinder block castings.

4. Developed and implemented FMEA, Control Plan, Process Flow Diagrams, Capability studies and SPC applications. Conducted internal quality audits and acted as lead area representative during Q1, TQE, QS9000, ISO9000 and Malcolm Baldrige National Quality Award audits. Plant achieved TQE ready status.

5. Designed, organized, conducted, analyzed and implemented results of many Design of Experiments (Taguchi Methods), resulted in significant scrap cost reduction and quality improvements at customer plants. Presented case studies at Symposiums on Taguchi Methods and received Awards.

6. Addressed customer quality related concerns using G8D format and presented to plant management.

7. Appointed as Technical Leader / Best Practice application engineer and provided guidance to cross-functional teams to resolve quality and productivity issues with a total savings of over $2M.

8. Developed and implemented many new ideas/changes to improve productivity, scrap reduction with alternative materials and tooling design changes, resulted in overall manufacturing cost reduction of $2M per year.

9. Received Customer Driven Quality Awards for achieving $2.5M savings in overall manufacturing cost reduction for 2.5L, 3.0L and 4.9L cylinder block castings.

10. Provided technical assistance to suppliers during their new product development with focus on productivity

improvement and environmental conditions resulted in annual savings of about $3M.

1. Conducted multiple business courses related to Casting defect identification and elimination, Design of Experiment (Taguchi Methods), Statistical Process Control, FMEA and Six Sigma Manufacturing Green Belt.

EDUCATION

M.S. Mechanical Engineering, May 1985

University of Akron, Akron, Ohio

B.E. Mechanical Engineering, India

(Valedictorian)

PATENT

U.S. Patent 5,368,087 approved for Hot Box Core Making Apparatus, December 1994.

PUBLICATIONS

1. Statistical Approach to the Cold Box Sand Mixing Process – Transaction of the International Foundrymen’s Society, 1987 volume 95.

2. 2.3L NVH Cylinder Block Process Optimization – Sixth Symposium on Taguchi Methods, November 1988.

3. Hot Box Sand Mixing and Core Making Process Optimization – Fifth Symposium on Taguchi Methods,

October 1987.

1. 4.9L Cylinder Block Bore Porosity Study – Fourth Symposium on Taguchi Methods, October 1986.

PROFESSIONAL AFFILIATIONS

1. Chairman – Northeast Ohio American Foundry Society Golf outing Committee, 2000-2006.

2. Northeast Ohio American Foundry Society – Board of Director, 2004-2005.

3. Member of the Executive Committee and Chairman of the Cure Sand Committee-4I, 1991-1992.

4. Member of Panel Presentation at 95th AFS Casting Congress.

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