Project Manager Engineer

SAMEERA MUTHYA

(MSIE/MSMSE, CAT Certified Six Sigma Green Belt)

Cell Phone: 806-***-****; E-Mail: *******@*****.***

CAREER OBJECTIVE

A Project Manager role with a solid organization that will offer both contribution and growth opportunities

CORE COMPETENCIES

CONTINUOUS IMPROVEMENT/KAIZEN

PROJECT MANAGEMENT LEAN MANUFACTURING

PROCESS IMPROVEMENT INDUSTRIAL ENGINEERING COST ESTIMATION

CAREER SUMMARY and ACCOMPLISHMENTS

9 years of industry experience in Industrial Engineering with excellent Project Management skills, spread

across heavy equipment manufacturing to Aerospace to metal fabrication and assembly industries

• Optimized manpower and line capacity on heavy equipment assembly lines, and identified cost

savings of $19.5M for CAT

Tools used: Time Study & Line Balancing, Manpower Analysis, and Continuous Improvement

• Secured DoD contracts worth $1.1M for Porter Manufacturing Corp

Tools used: Bidding/Cost Estimation

• Increased the process efficiency at Quality Coatings Inc., with a monthly savings of $13,000

Lean Manufacturing Tools used: Kaizen, Value Stream Maps, Kanban cards, JIT, 5S

• Increased production rate at Clean Foods Corporation (largest mango pulp extractor in India) via

process improvement, with a monthly savings of $3,300

Tools used: Cost Analysis, Waste Reduction, Energy Audit

• Reduced rejection rate of input housing castings by 53% at Hindustan Aeronautics Limited (Defense

and civil Aviation industry in India) with a direct cost savings of $1,250 per casting

Process Improvement Tools used: Pareto, Root-cause analysis, casting process improvement

COMPUTER SKILLS

MS Office (Excel, Project, Power Point, Word), Team Center, Made2Manage®, Computer Aided Process

Planning (CAPP+), Operation Data System (ODS), VIS View/VIS Mockup

WORK EXPERIENCE

SENIOR PROJECT ENGINEER – AUTOMOTIVE ROBOTICS (TIER 1 SUPPLIER TO CAT), Peoria, IL APR 2010 till present

Project Manager – Custom Petroleum Products, Caterpillar Inc., Griffin, GA (Jan 2011 till present)

• Kickoff and manage custom packaging projects for the factory from order to delivery

• Develop and maintain positive business relations with the dealers and customers by supporting

customer requests and meeting their delivery requirements

• Procure, store, and manage the parts for the Well Service Engineering prototype builds; Engage

customer and the engineering team in bi-weekly meetings to track material and order status

• Supported daily production for the well service product line and achieved high customer delight by

providing periodic updates on unit status and quick resolutions to production and material issues

• Managed the customer free-issued material inventory and coordinated with the supplier for timely

availability of material and sub assemblies to the CAT assembly line

• Introduced a pre-shipment paperwork verification process to eliminate defects (57%) in the data

sheets and the electronic test data shipped with each unit

• Maintained metrics and efficiently managed customer delivery schedules to help the factory achieve

delivery performance of 97% in 2011 and 99% in 2012, for the well service product line.

Project Coordinator – Assembly Planning, Caterpillar Inc., Griffin, GA (Apr 2010 to Jan 2011)

• Managed an offshore team in CAT India (team size: 4) to establish standard cycle times for all the

new operations through Time Standards; Coordinated the Virtual Build projects between CAT India

and the Griffin engineering teams from quote to delivery.

• Managed the offshore team’s workload through target-based project management and met all onsite

project deliverables and time lines

• Balanced the Engine assembly line to the Takt, maintaining the existing manpower and tooling;

improved the line efficiency by 60% through optimization and level loading of NPI engine

operations on the existing assembly line.

• Implemented NPI builds on the assembly lines working with the design support team and

successfully resolved documentation, line loading, and engineering issues.

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SAMEERA MUTHYA

(MSIE/MSMSE, CAT Certified Six Sigma Green Belt)

Cell Phone: 806-***-****; E-Mail: *******@*****.***

INDUSTRIAL ENGINEER – PORTER MANUFACTURING CORP., Lubbock, TX FEB 2009 to APR 2010

• Resolved production and engineering issues by engaging Operations, QC, and Engineering, in daily

meetings

• Drove engineering changes via efficient drawing accuracy and control, and reduced downtime

• Interpreted prints, ran BOM analysis, and collaborated with purchasing and suppliers to optimize

cost and increase profits for contracts

• Managed BOM, material and job routings, and schedules, to enable the shop achieve daily targets

• Methodically transferred drawings and generated NC programs to enable part fabrication

• Identified bottlenecks and eliminated non-value added time via time studies and process

improvement initiatives with Operations.

• Enabled the company secure contracts worth $1.1 Million by presenting highly competitive cost

estimations for DoD solicitations.

LEAD INDUSTRIAL ENGINEER – SATYAM (TIER 1 SUPPLIER TO CAT), Parsippany, NJ MAY 2007 to JAN 2009

Industrial Engineer - Assembly Planning, Caterpillar Inc., Decatur, IL (Sep 2007 to Jan 2009)

• Spearheaded the time study team (team size: 5) to provide cycle times to plan and document new

lines for assembling off -highway trucks and Wheel Tractor Scrappers at the facility.

• Created Spaghetti maps to identify non-value add times and drive Kaizen for rapid improvement

workshops and daily PDCA (Plan, Do, Check, Act) Operations’ meetings

• Provided root cause reports to Supplier Quality to reduce downtime due to material rework

• Identified an annual cost saving potential of $19.5 Million for the Decatur facility through line

balancing, level loading, and manpower optimization

• Interpreted prints and drawing notices to document engineering changes and successfully

implemented these changes through liaison and effective communication

• Trained on PSI project management success methods/techniques to successfully execute projects.

Project Coordinator - Product Finishing Group, Caterpillar Inc, Mossville, IL (May 2007 to Aug 2007)

• Trained on CAT Production System (CPS) 6Sigma Green Belt to document and leverage the Re-

deployable Paint System (R&D) project.

• Developed and maintained bi-weekly project charters, multi-generation project plans, and process

PMEAs, to line up with the ‘voice of the customer’ and CPS lean principles

• Documented the ‘Paint before Assembly’ process and created operation sequence to paint ECMs

and Starters based on future TAKT; Ran payback/ROI analysis to justify capital for the paint

modules at the new facility in Mexico.

INDUSTRIAL ENGINEER – QUALITY COATINGS, Lubbock, TX AUG 2006 to MAY 2007

• Implemented CI boards and 5S on the shop floor to initiate process improvement via increased

employee engagement. A productivity improvement of 8% (40 minutes per 8 hr shift) was achieved

through 5S, resulting in a monthly savings of $3700

• Introduced mixed-model scheduling to meet variable TAKT and reduce downtime (NVA) from color

changeovers by 45 minutes per shift, a monthly saving of $4000.

• Initiated in-process quality control and provided root-cause analysis to help QC identify and control

in process quality

KEY RESOURCE PERSON (GOVERNMENT CONSULTANT) - CLEANER PRODUCTION CENTER, India MAY 2001 to JUN 2002

• Identified non value added activities in the pulp extraction process through time studies and Pareto

analysis; Eliminated over-processing resulting in an overall savings of $3,300 per month

• Performed energy audits to identify sources of energy losses and implemented process

improvement measures to optimize energy consumption.

• Audited medium and small scale industries in Bangalore and documented the usage of ozone

depleting raw materials and waste/effluents

• Trained industries on ISO 14000 regulations and successfully setup a ‘Waste Exchange Bank’ to

help industries recycle waste and reduce the usage of ozone depleting substances.

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SAMEERA MUTHYA

(MSIE/MSMSE, CAT Certified Six Sigma Green Belt)

Cell Phone: 806-***-****; E-Mail: *******@*****.***

ENGINEERING PROJECTS

GRAD SCHOOL PROJECT – TEXAS TECH UNIVERSITY, Lubbock, TX

Lean Implementation in an industry – QUALITY COATINGS OF LUBBOCK, INC., Lubbock, TX JAN 2004 to AUG 2004

(Team size–3)

• Introduced one-piece flow and reduced the overall cycle time by 24 minutes by replacing the

existing product layout, with a process layout. A cost savings on $3000.

• Created pull system via KANBAN cards and JIT ordering systems, eliminating raw material and WIP

inventories, and storage. A total savings of $5,500 per month

• Level loaded final adjust and the shipping areas to relocate manpower to the extra sandblasting

booth, introduced to meet TAKT

• Used time studies to identify non-value added times and used value stream mapping to increase the

process efficiency of sandblasting and powder coating, to achieve a LPI goal of 87%

UNDERGRAD SCHOOL PROJECT

Rejection Control of input housing casting of an Advanced Light Helicopter [ALH] - HINDUSTAN

AERONAUTICS LTD. (DEFENSE AVIATION) Bangalore, India SEP 1999 to APR 2000

(Team Size–5)

• The team identified the critical defects (gas holes and high dense inclusions) causing the high

rejection rate (53%) in castings using Pareto analysis on the historic radiography test data

• The team worked with a Quality Circle to recommend better casting practices at the foundry via root

cause analysis of defects; Improved casting processes were introduced that reduced the rejection

rate from 53% to 9%, a savings of $1250 per casting.

• The team created and implemented a Visual Basic database to link the radiography department with

the factory foundry to improve data retrieval and eliminate manual record keeping.

EDUCATION

MS in Manufacturing and Systems Engineering (GPA: 3.6) – Texas Tech University, Lubbock TX Aug 2006

BS in Industrial Engineering and Management (Grade: First Class) – Bangalore University, India Sep 2000

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