Uday Nyalakonda

248-***-****/276-***-**** ( abjs74@r.postjobfree.com

( 35229 Pennington Drive ( Farmington Hills, Michigan 48335

Career Summary

Accomplished and results driven professional recognized for productive and

quality performance, commitment to excellence, and demonstrated ability to

communicate and work with senior management, associates, and customers.

Areas of expertise include:

. Excellent Strategist - Quickly identify and provide effective

solutions that boost productivity and efficiency across the

organization utilizing Lean Six Sigma methodologies.

. Project Management - Knowledgeable of business and management

principles involved in strategic planning, leadership technique, and

coordination of people and resources.

CAREER ACCOMPLISHMENTS

. Designed and built high volume Just in Time (JIT) green field plants

to supply automotive components from concept through Launch.

. Successfully completed multiple six sigma black belt projects with

over $2.5 million in cost savings.

. Trained, certified and mentored Green belts in DMAIC and DFSS

methodologies, Facilitated Lean Kaizen,TPS and 5S work shops in over

30 plants.

. Implemented innovative technology solutions to improve quality and

efficiency for which the plant received "2006 Assembly plant of the

year" award form assembly magazine.

. Developed, trained and deployed organization wide operational

excellence programs.

. Gained extensive international experience working in Brazil, China,

India, Mexico, South Korea, and Sweden.

PROFESSIONAL EXPERIENCE

Manufacturing Engineer / Supplier Development Engineer :

Gabriel Ride Control (Former ArvinMeritor Inc) ( Troy, MI

September 2008-Present

Project managed relocation and startup of a large manufacturing plant from

Toronto to Mexico. Responsible for evaluating, selecting and implementing

new technology to improve quality.

Key Accomplishments:

Developed layouts, capacity studies, capital investment requirements,

timelines and managed relocation of manufacturing processes from Toronto to

Mexico.

Championed extended value stream mapping process and identified key projects

to improve lead time from order to ship by 40%.

Developed and implemented shop floor metrics. Improved OEE in tube cutting

by 25%.

Led a team of managers and process owners in collecting key business

requirements for part traceability and converted into technical

specifications for ERP system upgrades.

Led a six sigma project which resulted in a reduction of scrap by 77% on the

tube mill. Developed and implemented a 100% inspection procedure to detect

seam weld defects.

Developed finished goods supplier strategy, identified and developed finished

goods suppliers in low cost countries like China and India.

Conducted internal and external supplier audits and maintained supplier

scorecards.

Lean Six Sigma Black Belt:

Manitowoc Cranes ( Manitowoc, WI

June 2007-September 2008

Lean Six Sigma Black Belt Consultant for a 750,000 Sq. Ft. crane assembly

plant.

Developed portfolio of projects, benefit analysis, scoping and executing the

projects to increase the plant capacity and efficiency. Trained and mentored

green belts (DMAIC) and blue belts (DFSS).

Lean Six Sigma Black Belt: (Continued)

Key Accomplishments:

Led a six sigma black belt project which resulted in cost savings of $1.1

million and a 70% reduction in overall lead time of major subassembly

components.

Conducted a company-wide lean gap assessment and identified projects to

improve efficiency in the plant which included developing extended value

stream maps.

Designed, and implemented "Field problem database" an internet based project

tracker and repository based on 8-D methodology.

Facilitated and documented "As-Is" and "To-Be" process maps to improve

customer service process. This also included warehouse and distribution

operations.

Performed process audits, developed statistical control charts and trained

process owners in their proper use for process monitoring and control.

Senior Advanced Manufacturing Engineer:

LEAR Corporation ( Southfield, MI

June 2002-January 2007

Managed all aspects of JIT facility/project management of new projects for

Automotive Interiors, from concept through launch in a turnkey operation.

Organized and facilitated DFM workshops with the design engineers to resolve

design issues.

Developed and audited equipment supply base in low cost countries.

Key Accomplishments:

Designed and implemented a facility layout and process for a Greenfield site

for seat assembly and JIT delivery of Nissan Altima and Maxima seats in

Smyrna, TN.

Designed and implemented a JIT seat assembly process for a state of the art

facility supplying seating systems to Hyundai. Effectively managed $9

million in equipment budget. The plant received "2006 Assembly Plant of the

Year" award.

Manufacturing engineering lead for consolidation of plastic interiors

business unit which involved closing down 6 plants and relocating the

manufacturing processes and infrastructure to other locations.

Senior Industrial Engineer / Six Sigma Black Belt (

June1994-May 2002

Designed, developed and implemented process for the JIT assembly of

automotive interiors including developing process layouts, labor standards

using MOST and simulation analysis.

Assisted Lear Sales Group in developing manufacturing plans for capital

budgets.

Key Accomplishments:

Completed four Six-sigma black belt projects with tangible cost savings of

over $900,000.

Represented Lear Corporation in "Kaizen the Kaizen" workshops sponsored by

Ford Motor Company.

Developed numerous discrete event simulation models to perform "what if"

analysis to predict the performance of the proposed manufacturing systems.

Developed and implemented web based labor standard reporting system.

EDUCATION AND TRAINING

Master of Science in Manufacturing Engineering:

University of Southern Mississippi ( Hattiesburg, MS

1993

Bachelor of Science in Mechanical Engineering:

Osmania University ( Hyderabad, India

1991

Software/Computer Skills: AutoCAD, Promodel, Minitab, IGrafix, Matlab,

Visio, MS Office.

~ Certified Lean Six-Sigma Black Belt ~

Lear and Manitowoc Six Sigma Programs

~ Project Management Training ~

Kelly School of Business - Indiana University ( 2008

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