Engineer Manufacturing

CAREER SUMMARY

Proven Manufacturing Engineer with seven years experience in optimizing

manufacturing processes for cost reduction, higher productivity and

improved product quality. Expert in Lean Manufacturing concepts, quality

control tools and production flow analysis. Successful track record as a

team leader with excellent communication and teaching skills. Self-

motivated, critical thinker with strong analysis, technical writing and

reporting capabilities. Additional skills include:

. Wear testing and tool coating analysis

. Design of experiments for improving engineering productivity

. Modeling and simulation of manufacturing processes

. CNC operation and programming

. Trained in SAP Material Management/Warehouse Management module

PROFESSIONAL SERVICE

Kennametal Inc., Latrobe, PA

2008 - Present

Product Development Engineer

Kennametal is one of the global leaders in manufacturing of cutting tools

for machining applications. The project involved product development from

conception to launch of two new products. The development team consisted of

ten team members. As a Product Development engineer, I have worked with

cross functional teams including design, research, manufacturing,

marketing, sales and quality control.

. Increased market share of 10% through the research and development of

modular drills for machining cast iron and ductile iron

. Improved tool-life by 100% through modeling, simulation and optimization

of tool-holder design using Ansys, Unigraphics and Deform for customer

application

. Project lead for development of new solid carbide drill for Aluminum

drilling

. Designed and executed experiments to develop and investigate drill

geometry parameter effects on tool-life and conducted performance

validation tests

. Worked in grade development of indexable drills for machining cast iron,

steel and stainless steel

. Worked on the design of a drill for machining Ti-CFRP composites

Semicon Inc., Lexington, KY

2007 - 2008

Manufacturing Systems Engineer

Semicon Inc. is one of the market leaders in manufacturing of porous

tungsten cathode dispenser tubes for Department of Defense (DOD)

applications. The project involved system optimization of current process

as well as development of a new process to improve productivity and reduce

scrap

. Improved productivity by 200% by optimizing cutting conditions and tool

grade

. Achieved cost savings of $100,000 due to reduction of scrap rate and

increase of tool-life

. Developed cryogenic manufacturing process along with documentation and

procedures and performed process optimization

. Developed predictive models for interrelationships between process

parameters and quality performance measures namely porosity and surface

roughness for process optimization

. Performed value stream analysis, statistical process control and Lean

manufacturing techniques to identify and eliminate root causes of waste

in the production line

Toyota Motor Manufacturing Kentucky (TMMK), Georgetown, KY

2005 - 2007

Manufacturing Process Engineer

Toyota Motor Manufacturing, one of the pioneers of the automotive industry,

needed optimization of their current manufacturing system at their

production facility. The system optimization was essential to reduce the

production cost of automotive cars while maintaining the highest quality

and reliability. I was a project lead managing a team of 10 members and

responsible for overseeing the complete project from experimentation to

validation

. Earned recognition for successfully leading a team of 8 & 10 team members

on two process improvement projects

. Improved tool-life by 200% through optimization of tool geometry and new

cutting tool design for a powder valves seat machining process

. Saved $220,000 annually by reducing scrap rate and tool costs due to tool

breakage

. Improved tool-life by 50% through optimization of cutting conditions

. Successfully established predictive models for interrelationships between

process parameters and tool-life

. Analyzed the effects of tool grade, composition and coating on tool-life

. Increased drill-life from 55 holes to 270 holes, an increase of about

500%, through optimization of drill geometry and cutting conditions for

crankshaft oil hole drilling process

. Saved $196,000 annually by reducing crankshaft scrap rate and tool costs

due to drill breakage

. Successfully managed a cross functional team of 5 team members

. Reduced drill breakage from 190 to 4 per month

. Studied and resolved the crankshaft oil hole drilling process for

variability such as drill alignment, process cycle time and crankshaft

material variation

Foam Design Inc., Lexington, KY

2003 - 2005

Manufacturing Engineer

Foam Design Inc., a manufacturer of form automotive components, wanted to

implement a new production system for manufacturing components for

Mitsubishi Motors. Line balancing, work allocation, improved productivity

and increased profit margins were achieved through design and development

of a new production system.

. Reducing lead time of production line by 20% through line balancing and

sequencing analysis

. Reduced setup time by 25% through development of cellular manufacturing

and group technology

. Designed and implemented production control for an automotive parts

production line

. Performed production flow analysis of various routings within the company

to form part families

. Performed value stream analysis to identify and eliminate root causes of

waste in the production line

Machining Lab, University of Kentucky, Lexington, KY

2001 - 2003

Research Assistant

Machining Lab at the Center for Manufacturing Systems is a research

facility at the University of Kentucky, specializing in research and

development of manufacturing processes. I have worked as a Research

Assistant and Editorial Assistant with responsibilities including research

and analysis, training, managing an international technical journal,

proposal generation, conducting seminars, presentations, labs and training

workshops.

. Successfully managed multiple Industry and government funded projects

ranging from $100,000- $ 750,000

. Successfully developed new optimization models for optimizing cutting

conditions and tool geometry in turning, milling and drilling to maximize

tool-life, reduce scrap and loss of productivity

. Built predictive performance models for optimizing machining of CoCrMo

used in Metal-on-Metal Hip Implants to improve the life of the implant

and minimize wear/debris generation

. Optimized PCD compact core drilling process on basalt for sustainable dry

drilling on Mars for reducing cost and increasing efficiency

. Investigated the influence of Minimum Quantity Lubrication in face

milling of automotive aluminum alloys

. Analyzed and optimized cryogenic machining of Inconel and porous tungsten

for improved part quality and accuracy for Aerospace and DOD applications

. Used lean manufacturing tools and techniques to optimize production

efficiency

. Used Finite Element Modeling softwares Ansys and Deform for stress and

failure analysis

Kirloskar Oil Engines Ltd, Pune, India

2000 - 2001

Industrial Engineer

Kirloskar Oil Engines is one of the leading diesel engine manufacturers in

India for commercial and domestic applications. I have worked as an

Industrial Engineer with responsibilities encompassing ergonomic work

station design, process improvement and quality assurance

. Performed Time Study and Line Balancing of the camshaft line

. Designed an Assembly Fixture for Camshaft and Cam Gear

. Applied Ergonomic Principles to workstation designs

EDUCATION and PROFESSIONAL DEVELOPMENT

PhD, Mechanical Engineering, University of Kentucky, Lexington, Kentucky,

USA, GPA 4.0/4.0

Thesis: Predictive Modeling and Optimization of machining conditions for

improved life of metal-on-metal hip implants

M.S., Manufacturing Systems Engineering, University of Kentucky, Lexington,

Kentucky, USA, GPA 4.0/4.0

Thesis: Tool-life Analysis of Crank Shaft Oil Hole Drilling and

Optimization

B.S., Mechanical Engineering, Pune University, India, First Class with

Distinction

Project: Assembly Fixture for Cam Shaft and Cam Gear

. Editorial Assistant for the Journal of Machining Science and Technology

(An International Journal)

. HAAS Certified CNC Machining Center Programmer and Operator

. Struers Certified Metallography Equipment and Techniques Operator

. Experience in working with Mazak turning centers with Fanuc controllers,

Automated Grinders

. Expertise in the use of a variety of metrology equipment including

toolmakers microscope, surface profilometer, coordinate measuring

equipment, digital/optical comparators, etc.

. Experience in working with scan electron microscopes, EDS analysis

methods, mechanical testing.

Computer Skills:

. Programming Languages: MATLAB, C++, FORTRAN

. Simulation Packages: Pro Model, ARENA

. Modeling Software: Deform, Ansys

. Other Software Packages: Auto CAD 2004, Pro/E,

Solidworks, Unigraphics

. Documentation Applications: MS-Office, MS Project, MS

Access, Visio, Adobe, and Corel

. Software Platforms: Windows, DOS

Member of Society of Manufacturing Engineers (SME)[pic]

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