JAY SANKARA

SUMMARY Jay has *+ years of experience in both technical and lead roles

in development and manufacturing environment. Progressed rapidly

through series of increasingly more responsible positions and

recognized for ability to lead both onsite and offshore teams in

developing/manufacturing of new products to achieve positive

outcomes. Jay is a results oriented professional able to work

effectively in teams or independently adhering to timelines and

provide cost effective solutions.

Product management

Customer driven Innovation

Product development cycle

Computer Aided Design

Strong quantitative analysis skills

Strong project & team management skills

Advanced communication skills

Vendor Management

. 5+ years in product design, mechanical analysis and project

management

. 4+ years in the development, reliability engineering of

Document feeders and Paper handling devices

. Design for manufacture (DFM), Design for assembly (DFA) and

Design of Experiments (DOE)

. Demonstrated excellence in Root cause & Failure analysis, FMEA

and solving system engineering problems

. Outcome driven Innovation, Lean product development using Plan-

Do-Check-Act cycles (PDCA)

. CAD: Solid/Surface Modeling, 2D/3D modeling and Drafting using

Geometric Dimensioning and Tolerancing (GD&T) in ANSI (Y14.5)

. Processing & Fabrication: Blow molding, Injection molding,

Thermoforming, Sheet metal, Machining and Brazing

. Managed communications with global suppliers in R&D and

manufacturing environment to finalize product design, cost and

manufacturability

. Experience in Lean manufacturing practices, Process

improvements, Value stream mapping and Cost reduction

activities

EDUCATION Certificate -Business Administration M.S - Mechanical

Engineering B.E - Production Engineering

University of Kentucky University of Kentucky

Osmania University

EXPERIENCE Lexmark International Inc., Lexington, KY

May'05 - Present

LEAD PRODUCT DEVELOPMENT ENGINEER

New Product Introduction (NPI) for Mid-range Multi-function

Printers and Scanner R&D

> Evolved product from concept stage to successful commercial

launch and through 5 subsequent releases and sales to 200+

primary customers like Dell, Toshiba, and IBM.

> Market research and analysis for establishing product

requirements

> Primary liaison on several new products inception into

consumer markets involving several team members spanning

across research, marketing, design, manufacturing and

quality assurance areas.

> Suggested several cost effective initiatives in the areas

of product design and mechanical aspects which evolved in

$3.6 Million of cost reduction in manufacturing and speed-

to-market costs.

> Responsible for delivering document feed performance with

little or no user intervention

> Responsible for reviewing several engineering activities in

planning, testing and design/redesign of the scanner

without compromising on the industry standards.

> Rendered product technical specifications for several Sub-

systems and mechanical components

> Collaborated with Product teams on system architecture for

commonality of tooling and minimize capital expense by 30%

> Monitored quality metrics on product performance in the

consumer market and revised process and product

improvements

> Coordinated and ensured quality on cross-functional team

deliverables adhering to strict timelines without

compromising on the quality of the deliverable.

> Conduct timely status meetings with team members at various

phases of the product lifecycle to capture the progress and

provide feedback to senior management and enforce strict

project timelines.

> Provide accurate solutions on production line problems,

especially line stoppages, by analyzing the problem,

determining root cause, and recommending counter measures

to restore production activities within 24 hours

HARDWARE ENGINEER

Hardware development responsibilities on Low-End Multi-function

Printers

> Lead Mechanical engineer on X360 and X460 product families

through the product development cycle of prototype

development to manufacturing integration

> Designed and developed mechanical paper path components for

document feeders and product assemblies from industrial

design concepts

> Identified infant mortality problems and manufacturing

defects before the product reaches the market by

Reliability testing such as HALT, Corner Testing, MTBF

> Project Lifecycle Management (PLM) of component drawings,

assemblies, details & specifications

> Performed drop, vibration, thermal and acoustic testing and

make necessary design changes to ensure the product passes

the DVT exit stage

> Responsible for product regulatory compliance & associated

testing

> Familiarity with Agency approvals for EMI/EMC/Acoustics and

Product Safety

ELECTRONICS PACKAGING ENGINEER

Packaging design and testing responsibilities on Ink-Jet, Laser

printers and supplies

> Optimized packaging layouts, Shipping configurations to

minimize the packaging & shipping costs

> Designed packages of inkjet and laser printers for Drop,

Vibrate, Ship, and Altitude testing as per ASTM test specs

> Interfaced with model shop for fabricating prototype EPS

for testing and evaluated the best design that meets cost

and quality objectives

> Sourced carton and cushion samples of different cushion

materials from suppliers and qualified them for Production

> Prepared several 2D, 3D drawings and made engineering

changes (ECN)

Systems Labs, University of Kentucky, Lexington, KY

Jan '05 - May '05

ENGINEERING LAB CONSULTANT

Responsibilities include general Lab administration at several shifts

> Supported, maintained CAE Software/Hardware administration

& reduced the downtime by 18%

> Taught users proper usage of PC applications and

PDM/PLM/CAE software tools

> Instructed undergraduate students on fundamentals of CAD

Modeling using IDEAS

Center for Manufacturing, University of Kentucky, Lexington, KY

Aug '03 - Jan '05

RESEARCH ASSISTANT

Research on Sustainability analysis of automotive heat exchangers

manufacturing furnace

> Evaluated the energy efficiency of a brazing furnace using

thermodynamic figure of merit.

> Collected data from Industrial setup & established test

routines to evaluate the energy usage of CAB process

> Extensively used spreadsheets/database to sort, identify

and analyze experimental and test data

> Identified & proposed process improvements to optimize the

energy usage & reduce environmental hazard

Shriram fuel Injections, Hyderabad, India

May'00 - Jun '03

PROCESS CONTROL ENGINEER

Process Improvement responsibilities in an ISO 9001 company.

> Implemented 5S, Visual control and formulated standardized

work

> Review supplier manufacturing processes and quality

systems.

> Function as liaison between purchasing, engineering,

manufacturing and suppliers to resolve supplier quality

issues and to provide technical support.

> Determine cause of supplier quality problems and

coordinate/implement effective and timely resolutions

> Improve quality performance of suppliers by conducting

workshops at supplier locations, providing technical

assistance in developing a quality system, or other

technical support as required

> Implement and monitor the part qualification and

certification process with selected suppliers. Maintain

required documentation and files

> Quality Initiatives executed on time and with rigorous

discipline for targeted suppliers. Report expectations met

in a timely manner

Operating Systems: Windows, Unix and Macintosh

Email Software: Lotus Notes, Microsoft Outlook

Documenting: MS-office Suite, Adobe and Corel

CAD/CAE: NX, IDEAS, Pro/E, Ansys

PLM Applications: EDIS, LPCS, Matrix- Enovia

Project/Product Mgt.: Microsoft Project, Vision

Statistics: Minitab, Statistica

Programming: C, Fortran (1 year), C++, Lab view,

Minitab

. LINCS (Lexmark Integrated Network CAD/CAM Systems) - PLM

certified LEVEL-I, IDEAS user.

. Element K certified Matrix-Enovia PLM: Basic User

. Six Sigma Yellow Belt Training - Lexmark Six Sigma e-Yellow

belt: Manufacturing

. Completed Certificate training in Mechanical Design using CAD

software - IDEAS, Pro/E, and NX.

. Designed, Developed and Tested packages for inkjet, laser, and

all-in-one printers - For Dell Inc, TX.

. Developed an Exergy based method for a sustainable CAB system -

For Delphi Automotive Systems, NY

. Value Stream Mapped a cylinder manufacturing cell - For UK

Center for Manufacturing, KY

. Designed an Automatic stacking system of Aluminum Bus bars -

For Square D, KY

. Designed and Evaluated substrates for paint sprayer cup - For

Toyota (TMMK), KY

. Modeled and Simulated working of an inline flat IC-engine in

IDEAS- For EDS PLM users conference '02

. Modeled and Developed a go-kart using IDEAS - For EDS PLM users

conference '01

. Designed and Manufactured an Automatic Shielded Metal Arc

Welding System (SMAW).

. Awarded Kentucky Graduate Scholarship by University of Kentucky

. Awarded Scholarship grant to partake in International

Mechanical Engineering Congress (IMECE- 2004) by the University

of Kentucky.

. Awarded Travel assistance to participate in 39th annual

technical meeting of Society of Engineering Science (SES-2002)

by Penn State University.

. Awarded Second prize for Design contest-Propositum,

Mechanica'02 by CBIT, India.

. Awarded Second prize for paper titled "Performance Evaluation

of a Modified Single point cutting tool" at a National level

technical symposium-Mechmantra'02 by RVR & JC, India.

. D.P.Sekulic, J.Sankara "Advanced Thermodynamic metric for

sustainability analysis of continuos manufacturing system" 2005

International Journal of Thermal Science.

. J. Sankara, D.P Sekulic "Irreversibility approach for

sustainability analysis of a continuous Net shape manufacturing

system"- IMECE 2004 ASME Transactions.

. J. Sankara, F. Bryan and D.P. Sekulic "Exergy approach for

sustainability analysis of a net shape manufacturing processes"

Proceedings of Second Annual Kentucky Innovation and Enterprise

Conference, March 3, 2004, Louisville, Kentucky.

. J. Sankara, K. Kishore "Performance Evaluation of a Goose

necked cutting tool"; Bangladesh 2003

. J. Sankara, K. Kishore "Performance Evaluation of a single

point cutting tool"; IITM Shaastra 2002

. J. Sankara, "Tool Condition Monitoring using Multi-sensor

fusion techniques"; 39th Annual Technical Meeting of Society of

Engineering Science (SES2002) October 13-16 2002, Penn State

University.

. J. Sankara, "IDEAS as a virtual simulator", EDS PLM Users

conference-2002, Bangalore, India.

805 Mickey lane, Lexington, KY 40509

Tel: 859-***-****, E-mail: abmwqm@r.postjobfree.com

STRENGTHS

COMPUTER

SKILLS

CERTIFICATIONS

PROJECTS

HONORS

PUBLICATIONS

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