Engineer Quality
Resume:
Rehan Ali Khan (CSSBB CAT, CSSGB ASQ)
(Cell): 309-***-****
Peoria, IL, 61525
Email Address: *******@*******.***
___________________________________________________________________________
OBJECTIVE:
Seeking a fulltime position in the field of product development, quality
and reliability engineering
CAREER PROFILE:
. Currently working in Caterpillar Inc.(Commercial engines) as a product
Sr:Quality engineer
. Sr: Quality Engineer in Methode Electronics Inc.
. "Customer Quality Engineer" in Hi-Lex Controls.Inc
. Reliability Implementation Engineer in Ford Motor Company.
. 1-year experience as an Application Engineer in American Axle
Manufacturing.
. Knowledge of DOE, Robust Design (Taguchi Method), DSFSS (On Job DMAIC 5
Day Class)
. Knowledge of Regression Model (Course completed via American Society
of Quality) and Response Surface Methodology, FMEA, JIT, APQP, PPAP,
QS9000, ISO9000, AWS, CQIS.
. Certified Six Sigma Black Belt from Caterpillar Inc, Total Quality
Management (Course completed via ASME)
. Certified Six Sigma Green Belt from American Society of Quality
. Completed one day seminar on "first time supervisor"
. Strong Problem solving skills including basic problem solving tools
like 5 Whys, 8D's, Hi-Fives, Fishbone diagram, Is and Is not matrix.
WORK EXPERIENCE
Sr:Quality Engineer. (Caterpillar Inc. )
March08-Current
. Responsible for VEHR trends and drive the corrective actions as per team
decision
. Responsible for dealing with CPI issues assigned for the commercial
engine group
. Heavily engage with emerging quality issue, primarily product related but
not limited too
. Involve in assigned customer issue and involve responsible personnel to
implement the corrective actions
. Periodically use RWA, QRWB, HVC (several applications), TMI, and SIMS to
extract the information needed towards the resolution of specific issue.
Quality Engineer. (Methode Electronics Inc)
Feb 2005-Mar-08
. Responsible for multiple platforms and new launches. (Clock spring
assemblies, Transmission lead frame)
. Interact with customers and suppliers to resolve quality issues.
. Initiate investigations of quality measures, review gage R&R inspection
reports.
. Determining and implementing corrective actions through the use of DFMEA,
PFMEA and APQP.
. Participate in design and manufacturing reviews, analyze warranty issues,
prepare control plans and maintain documentation to ensure compliance
with customer specifications.
Customer Quality Engineer (Hi-Lex Controls.Inc)
Feb 2003-May 2004
. Responsible to meet quality standards of the finished products (Quarter
Vent Actuator Assembly/Window Closure Mechanism) to customer.
. Resolve customer issues and documentation.
. PPAP (as per SQAM and ANPQP manual) submission (including documentation
required to fulfill customer format and program approval) and execute
APQP/ANPQP mile stones.
. Implement irreversible corrective actions on basis of customer
complaints and kickoff engineering change based on analysis results.
. Provide launch support at customer locations and interface between
plant, product engineering and customer.
Reliability Implementation Engineer (Ford Motor Company)
June 2002-Oct 2002
. Core team member for Priority System in leading programs.
. Core team/Support member in Hi-Mileage Projects.
. Responsible for Fuel Pump System Failure Project for vehicle lines
(Lincoln LS, Town Car, and Grand Marquis) etc.
. Analyze statistical data by using AWS (Analytical Warranty System) and
resolve team issues.
. Work closely with external suppliers and ensure Reliability and
Robustness disciplines, NFMM (Noise Factor Management Matrix), RRCL
(Reliability and Robustness checklist), RDM (Reliability Demonstration
Matrix), DFMEA, PFMEA, RSOW (Reliability Statement Of Work), P-Diagram,
Block Diagram, DMAIC (5 day Six Sigma Green belt internal training) etc
are implemented and executed properly.
. Play core team member in problem solving team and use tools like Global
8D, Root Cause Analysis, DOE
Application Engineer (American Axle and Manufacturing) Aug
2001-June 2002
. Product development, design, and product validation.
. Develop concept of product according to the customer requirements and
specifications.
. Work closely with design and analysis teams to resolve critical product
issues.
. Approve prints are from customer (DaimlerChrysler) and source of
components.
. Work as a Liaison Engineer between product engineering and customer
facilitating design activities.
. In order to validate design, develop specific mechanical tests like
torsional fatigue, NVH test on Chassis Dynamometer, Multi-block Cycle
test (DaimlerChrysler) etc.
. Release engineering prints after customer and product engineers
approve.
. Work closely with DaimlerChrysler CAD and FEA engineers to resolve
component issues.
EDUCATION:
. MS Mechanical Engineering Wayne State University
April 2001
. B.E. Mechanical Engineering N.E.D. University. Karachi. Pakistan.
August 1998
COMPUTER SKILLS
Operating Systems WINDOWS 95/98,UNIX, DOS,
SUNSOLARIS.
Application Soft wares MATLAB, MS OFFICE, MATHEMATICA,
MINITAB 14&15
FEA solver NASTRAN, LS-DYNA.
CAD software HYPERMESH, AUTOCAD R-12,
DYNAFORM.
Gross motion simulator. MADYMO5.4
WORK RELATED PROJECTS:
Engineering Experimental Design (DOEs):
. Perform design of experiment in ultrasonic welding process to optimize
the process parameters. (Important factors Ampltiute, time) using
Minitab
. Perform design of experiment in resistance welding process (work with
core team and consultant) to to optimize the process parameters
(Important factors: Weld time, Weld current, Uptime, Force) for T-76
Lead frame, 1/2 factorial with one center point using Minitab
Six Sigma Process Improvement Projects:
. Apply DMAIC loop in Scrap reduction on clock spring lines with ongoing
improvement and downward trend in DPMO over the time period.
. Apply DMAIC in the SPC measurement method (was causing unnecessary
scrap), and devised new control chart to qualify non-conforming data
points. (Which resulted in less rejection without affecting the ongoing
customer quality)
Regression Analysis:
. Perform linear regression analysis in the ultrasonic welding process
between process parameter and pull test results to identify correlation
among them.
COURSE WORK PROJECTS
Engineering Experimental Design
. Design and analysis of factors affecting hardness of metal piece by
utilizing factorial design with material as blocking factor.
Quality Engineering
. The application of TAGUCHI METHOD to design an automobile seat. The paper
discusses the variable that may affect and TAGUCHI METHOD is used to
examine those variables and discuss how this variable may affect a
rider=s comfort. The paper also covers the comparison of other method
that can be used to design an automobile seat using design of experiment
technique.
REFERENCES
Will be furnished upon request.
Contact this candidate