Customer Service Engineer

SUDHIR ALCHURU

**** *** ****** *, ********* VA **205

703-***-****, abmhd8@r.postjobfree.com

SUMMARY

High energy, results oriented management professional with over five years

of diversified experience in automobiles, pharmaceutical, hi-end

manufacturing, meat and archival industries. Experience includes a strong

background in program development, implementation and training. In-depth

knowledge and hands on experience in process improvement, quality control,

inventory management, supply chain optimization, total quality management,

process re-engineering, facility layout, health& safety, and ergonomics.

Excellent interpersonal and organization skills; proactive team player;

strong analytical and problem solving skills.

. Successfully led cross functional teams in high pressure, time

sensitive assignments

. Certified Six Sigma Black Belt; proficient in ISO

9000/9001/9241/14001, ANSI/BIFMA/HFES Standards

. Areas of expertise include Six Sigma, Lean Manufacturing, FMEA, 5S,

Kaizen, CAPA, Statistical Data Analysis, SPC, Facility Layout Design,

Posture Analysis, and Ergonomics Evaluation

CREDENTIALS AND PROFESSIONAL HONORS

. Master of Science in Industrial Engineering, University of Nebraska -

Lincoln GPA: 3.5 (May 2005)

. Bachelor of Mechanical Engineering, University of Madras, India

GPA: 3.7 (May 2002)

. Six Sigma Black Belt, ExpertRating

(May 2010)

. Associate Ergonomics Professional, #1368, Board of Certification in

Professional Ergonomics (April 2007)

WORK EXPERIENCE

Manager (Engineering), Oakton Technologies, Woodbridge, VA

July'09 - Present

(Clients: Subcontracting for JFAssociates Inc., Technology Associates

International Corporation)

Responsibilities include establishing new business contracts with

government/commercial businesses and provide technical direction in

business process re-engineering, process improvement, facility planning,

ergonomics and occupational health & safety programs. Functional

responsibilities include defining, planning, implementing and managing all

aspects of technical development from conceptual approval to production,

budgeting, and generating reports; lead and educate cross functional teams

to implement quality and continuous improvements projects for the clients;

planning the schedules of individual team members, and matching them to the

overall project milestones and objectives

Key Accomplishments

. Increased labor efficiency 23% for a warehouse/distribution center by

implementing a training program which used employee input and

involvement ; assisted the client in the implementation of Warehouse

Management System

. Created annual and preventive maintenance program for both

manufacturing equipment and facilities which resulted in greatly

reduced downtime savings of $225,000/year for a meat manufacturing

company

. Implemented cellular manufacturing for an automobile part industry,

reducing lead time by 18% while improving productivity by 13% and cost

saving of $400,000 in four months period

. Reduced inventory 20% and decreased the purchase & handling cost 21%

by implementing JIT purchasing and consignment for a fortune 100

business agency

Quality Specialist, Technology Associates Intl Corporation, Mclean, VA

Nov'07 - July'09

(Clients: International Monetary Fund, World Bank, Iron Mountain Archival

Facility, Continental Teves)

Responsible for developing strategic programs to improve operating costs

and organizational efficiency for clients. Assist the clients in

evaluating, improving facilities & planning, developing time frames and

cost structure favorable to marketing strategies. Manage contracted

projects from conception to first production.

Key Accomplishments

. Re-engineered ordering/fulfillment process from paper to touch tone

electronic entry reducing the error rate by 23%; Enhanced the standard

operating procedures (SOP) for the archival and shipping departments

. Utilized Six Sigma Methodology (DMAIC) to analyze the critical factors

that influenced the scrap rate of brake pistons and brake pad products

for an automobile parts manufacturing company; implemented changes to

minimize the scrap rate by 21% and reduce lead time by 12%

. Utilized Six Sigma methodology and developed a web-based database for

ergonomic job analysis and evaluations

. Identified the severity of risk involved in the current material

handling process using FMEA methodology for an archival facility;

recommended effective countermeasures to reduce/ the severity of the

risk

. Ergonomic intervention on work stations resulted in minimizing risk

factors by 73%, pain symptoms by 57%, and cost savings of more than 4

million dollars

. Trained over 3000 personnel from various organizations on 5S, Lean

Manufacturing, TQM and ergonomics

Industrial Engineer, JFAssociates Inc., Fairfax, VA

Sep'05 - Nov'07

(Clients: International Monetary Fund, Federal Reserve, West Virginia

Hospital, Sanofi Aventis, Tyson Chicken, Georges Chicken, Sara Lee Foods,

Koch foods)

Responsibilities include performing audits, and detailed studies leading to

improvement of existing products and process. Responsible for data

gathering, analysis, and presenting recommendations for improvement.

Key Accomplishments

. Utilized value stream mapping and lean technique tools to reduce lead

time and improve productivity for meat packing, and pharmaceutical

industries

. Provided facilities layout solutions to a meat packing industry and

improved space utilization by 17% using simulation tools, which

minimized the labor cost by 24%, and productivity increase of 19 %

. Improved line efficiency for a pharmaceutical industry by 12.4% by

applying time study & work measurement tools

. Enhanced the quality control procedures and established SPC charts to

monitor and control the meat packing process

. Trained over 2000 personnel from various organizations on 5S, Lean

Manufacturing, TQM and ergonomics

. Redesigned mechanized and automated equipment and recommended changes

in work practices to reduce the risk of injuries for industries

including automobile part manufacturer, pharmaceutical,

transportation, and meat industry

. Performed proactive/reactive workstation evaluations and recommended

effective countermeasure to reduce/eliminate the work related

musculoskeletal disorders for several clients

Industrial Engineer Consultant, University of Nebraska Press, UNL

July'04 - Feb'05

Responsible for efficient utilization of labor in customer service,

warehouse, packaging, and shipping department; implementation of process

improvement projects; train the personnel on new techniques and methods;

reduce work related injuries and improve safety at work place. Work with

senior management and users to effect process change and improvements.

. Improved turnaround time for the books printing process by 23.5% using

six sigma methodology

. Implemented lean manufacturing principles to reduce the lead time for

processing an order from 120hrs to 72hrs

. Implemented the Automated Postal Processing System (SECAP) for the

shipping and customer service department resulting in a cost savings

of $150000/year on shipping and labor costs

. Enhanced the standard operating procedures (SOP) for the

shipping/receiving/warehouse department and implemented 5 S

methodology in the shipping department to improve safety and

efficiency of the employees

. Conducted time and motion studies to analyze the job content for the

all the shipping and warehouse operations

. Conducted ergonomic evaluations in the packaging stations (packing

tables, utility knives and packing materials) to improve safety,

quality and reduce time and cost of packaging process

Research Assistant, Department of Industrial Management & Systems

Engineering, UNL May'03 - May'05

. Designed 48 commonly adapted postures by the construction workers

. Developed a rating scheme to evaluate the severity of 48 postures

. Developed a software based Postural Evaluation Tool (PET) to evaluate

the severity of the construction tasks

. Tools Used : Sampling plan, Interviews, Videotape Analysis, SAS,

Microsoft Access, Visual Basic

Manufacturing Engineer, KCP Sugars LTD, Andhra Pradesh, India

Aug'01 - June'02

. Teamed with Quality Engineer and developed FMEA and control plans for

reducing the wear and tear

. Analyzed and implemented changes to decrease the downtime of the

machines by 17% in the sugar production mills

. Coordinated with internal and external suppliers for effective

maintenance of supply chain

. Worked in a team oriented environment for production and quality in

support of all production requirements

. Implemented 5 S methodology to improve safety and work efficiency

. Tools Used : Ishikawa Diagram, FMEA, Brain Storming, Cost Benefit

Analysis, 5 S principles, QFD

SOFTWARE SKILLS

. Statistical : SPSS, SAS, Minitab

. Design Packages : AutoCAD, PRO-E

. Optimization : Arena, Simul 8

. Others : Microsoft Office Package, Microsoft

Project, SECAP, Q&A

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