Quality Engineer

Location:

Decatur, AL, 35603

Posted:

August 13, 2010

Contact this candidate

Resume:

Ramesh V. Madhav

**** ******* ***** ** (ASQ - CQA, CQE, CQT) Home 256-***-****

Decatur, Alabama 35603 ablx1l@r.postjobfree.com Cell 256-***-****

Thorough and precise Quality Professional with broad range of experience in

Automotive, Aerospace, Rubber / Plastic Molding, Electronics - printed

Circuit Boards / Medical Devices, Sheet Metal and Machine Shop Industries.

Aggressive problem solver with excellent technical and analytical skills.

Team player who can deploy Lean Manufacturing Principles effectively.

Strong organizational, planning, leadership, administrative, interpersonal,

and multi-tasking skills. Eager to learn new concepts and willing to accept

challenges. Certified Six Sigma Green Belt. U.S. Citizen, eligible for

security clearance.

Key Accomplishments

> Six Sigma Green Belt Project: Reduced FP20 Coating Scrap by $11,000

per month with labor savings of 34,000 per year

> Reduced cycle time 25% on Contour checks by eliminating unnecessary

steps

> Eliminated waste by organizing fixtures, gages and check sheets

files near work area

> Reduced scrap to less than 0.50 % with savings of $50,000

> Negotiated purchase of Contracer equipment saving company $25,000

> Senior Member of American Society for Quality (ASQ)

> Nominated as a Quality Professional for the year 2004-2005 (ASQ-

Huntsville, AL Section)

> Instructor of ASQ - Certified Quality Engineer and Metrology

courses

> ASQ-Certified Quality Auditor, Certified Quality Engineer and

Certified Quality Technician

EMPLOYMENT HISTORY

Federal Mogul - Sealing Systems, Athens, AL 1991-2009

Quality Engineer

Processes: Metal Stamping, Forming, Screen Printing, Coating, Eyeleting,

Spot and Laser Welding.

Managed Quality Function for "Gasket" Group. Created Process Flows,

Process FMEAs, Control Plans, Inspection Plans, Visual Standards, Work

Instructions, Procedures and Check Sheets.

. Managed advanced product quality planning (APQP) projects for new

parts, and control of engineering changes (ECN / PCN). Submitted

sample parts and Production Part Approval Process (PPAP) package

for customer's approval.

. Conducted gap analysis, and implemented necessary changes to comply

with ISO requirements.

. Performed Internal Quality System Audits, Follow-up Audits, Process

Audits, and Safety Audits (Stop - Observation).

. Developed Audit Plans, Checklists and conducted Internal Audits as

per schedule to verify Quality System Compliance.

. Reviewed Design FMEAs and DVP&R. Conducted engineering drawings

review and manufacturing feasibility.

. Conducted T-test to determine any significance difference between

before and after change.

. Trained employees on quality system procedures, work instructions,

measuring instruments techniques, and blue print reading.

. Developed, mentored, and led cross-functional teams, established

goals, created a positive environment to achieve desired results.

Worked on Continuous Improvement Projects, applied Six Sigma DMAIC

Methodology and Lean Manufacturing Concepts (5S, Kanban, Single

Piece Flow, U Cell Formation, and Value Stream Mapping).

. Eliminated assignable causes by investigating and conducting root

cause analysis (RCA), implementing corrective and preventive

actions (CAPA) and verifying the effectiveness.

. Performed product line verification/validation and Process Sign-off

which included verification of process capability, capacity

analysis and run-a-rate for the product line.

. Monitored Cost of Quality, which included Prevention, Appraisal,

Internal and External Failure Costs. Analyzed and verified customer

returns, prepared technical reports on the results. Chaired

Material Review Board (MRB) and made disposition on non-conforming

material.

. Established SPC methods, and data collection system. Analyzed data

and presented reports.

. Performed gage design reviews, gage R & R, Pareto analysis, and

process capability studies.

RAMESH V. Madhav Page 2 of 2

Van Dresser Corporation, Westland, MI 1989-1991

quality engineer

Processes: Forming, Water Jet Cutting, Vinyl Bonding and Assembly.

Primary Quality Contact responsible for up to 100 Million in accounts

with 4 different customers.

Managed advanced product quality planning projects for new products and

prototypes. Submitted production samples for approval. Reviewed check

fixture design and obtained buy-off approval from tool shop. Conducted

Supplier Audits, interacted with customers and suppliers on Quality

System requirements and problem resolution.

. Established quality system plans meeting requirements of Ford, GM,

Chrysler and Toyota.

. Assured manufacturing quality control including training

inspectors, solving manufacturing quality problems, and making

decisions on parts' acceptance and rejection criterion.

. Visited suppliers for tools / equipment trials and validation,

performed capability, and run-a-rate to substantiate the approvals.

Thunderline Corporation, Belleville, MI 1985-1989

Quality Engineer

Processes: Silicone/Rubber/Plastic - Transfer & Injection Molded Parts, and

Assemblies.

Conducted SPC training. Established inspection and lab test procedures.

Performed First Article Inspection, and submitted PPAP package as per

customer's requirements. Served as customer liaison.

. Managed Quality Function and supervised 10 Inspectors. Established

quality system and procedures as per Automotive / Aerospace

industry requirements.

. Acted as Quality Manager overseeing one facility for 1-year.

Ann Arbor Circuits Inc., Ann Arbor, MI 1983-1985

Quality Assurance Supervisor

Processes: Printed Circuit Boards - Shearing, Punching, Printing, Etching

and Plating.

. Evaluated performance of inspection personnel, trained, and

Supervised 6 inspectors.

. Established Statistical Process Control methods, inspection

procedures and quality standards as per IPC / FDA / Military

requirements.

. Assured quality of Printed Circuit Boards and solved quality