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Project Quality, Manufacturing, Product, Process Quality, ISO, API

Location:
Houston, Texas, United States
Salary:
96,000.00
Posted:
August 28, 2017

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SREEVATSA CHAKRAVARTHY (US Citizen)

Houston, TX *7059 C: (832) ***-**** ac11tu@r.postjobfree.com

Summary of Qualifications

Manufacturing & SQA; PLM; MBOM

Continuous Improvement (CIP); MRB

ASME B&PVC Sections II, VIII, IX, V

ASME B31.1; B31.3, B31.9, B16.5;16.34, ASTM; NEC

Lean Manufacturing; RCA (5WHYs, Fish Bone diagram)

Corrective action (Six Sigma/8D); ECO/ ECR

QMS (CAPA); CAR; PAR; NCR; COPQ; Composites

APQP; Lean& Six Sigma Tools; PPAP; ISO/ TS 16949

Customer Complaints & NCR Resolution; Control Plans QITP, Quality Data Books, Quality Metrics, KPI

ISO9001-2008; ISO14001-2004

ISO 17025-2005 (Calibration)

API Spec Q1; API 661, RCFA; FMEA

Metallurgy & Design Engineering

Major Critical Equipment Inspections

AWS D.1.1; AWS D1.3; WPS; PQR

Fabrication (welding methods, procedures)

Corrosion & Mitigation Engineering

Project Mgmt & Project Quality Plans

Product Test (NDE, Helium Leak, Hydro)

Supplier Management; Supplier Quality Score Card(DPPM metric) Risk Management(FMEA); MAS 500(ERP)

Welder Continuity and Traceability; FAI NDT (LPI, Hydro, MPI, VT, RT, UT, PMI)

ASME Code (ASME “U”, NBIC “R”) Metal Fabrication; PED;ATEX

Professional Work Experience

Quality Manager (Project Quality, Manufacturing, Product, Process Quality, Supplier Quality, ISO Certs, Customer Relations) December 2015 – Feb 2017

TAS Energy Inc., Houston, TX

Achieved a 50% cost reduction in NDE contractor inspection costs.

Possess Strong working knowledge of ISO 9001; API Spec Q1; ASME Code (ASME “U”, NBIC “R”); API 6D, API 661, API 598; ASME B&PVC Sections II, VIII, IX, V; ASME B31.1; B31.3, B31.9, B16.5, B16.34

Manage customer audits including 3rd party welding audit, 3rd party Quality Management System (QMS) audits and corporate quality audits achieving customer satisfaction at completion.

Manage 3rd Party ISO 9001-2008 certification audit.

Manage welding program including rework of Welding Procedure Specifications (WPS), PQRs and welder certifications while meeting stringent, project specific customer welding code requirements.

Maintain effective supplier management system through communication, issue resolution, supplier audits and conducting inspections and factory acceptance testing (FAT) at supplier facilities for major equipment providers (both domestic and internationally).

Conduct internal factory acceptance testing (FAT)(Hydrostatic Testing, Pneumatic, Helium Leak Testing)

Work closely with Engineering, Project Management, Supply Chain, Sales and other functional teams to ensure overall project quality and customer satisfaction.

Developed and implemented NCR (Nonconformance Report); CAR (Corrective Action Report); SCAR (Supplier Corrective Action System) programs and ensure root cause solutions are identified and implemented.

Driving the organization toward data based decision making, by developing and implementing appropriate data collection methods to provide relevant and actionable data for suppliers and operational departments, both in house and at project sites.

Senior Quality Engineer (Manufacturing, Supplier Quality, Product, Process Quality, ISO, API, Customer Complaints) November 2011 - November 2014

Mitsubishi Caterpillar Forklift America Inc. (MCFA), Houston, TX

ISO 9001-2008 (Quality Management), ISO 14001-2004 (Environmental Management) & OSHAS 18001 Certified Internal Auditor. Liaison between registration body (DNV) (3rd Party Audits) and MCFA Management for ISO 9001 & ISO14001 certifications.

Possess work experience in APQP advanced quality planning (design reviews, Design FMEAs, Process FMEAs, print reviews, Process Control Plans, Gage R&R ), assisted suppliers with Advanced Product Quality Planning (APQP) activities to ensure production readiness for New Product Introduction (NPI); ensured PPAP completion and approval prior to delivery of new parts

Maintained ISO Program, internal quality audits, document and data control. Created/revised procedures as needed and provided training. Conducted Quality Audits of Suppliers and Potential Suppliers.

Possess strong working knowledge of ISO 9001(2008), ISO/ TS 16949& API SPEC Q1.

Worked as a lead for Root Cause Analysis (RCA); root cause corrective action methodology (Six Sigma/8D); CAPA; NCR; Corrective Action Plans (CAR) Preventive Action(PAR).

Implemented and enforced the QMS System CAPA (Corrective Action Preventive Action process), RCA (Root Cause Analysis); and NCR reports and reduced the Cost of Poor Quality from 10% to 1%($1.5 M savings).

Developed and trained company employees on CAPA (Corrective Action Preventive Action process), RCA (Root Cause Analysis) and NCR processes.

Maintained Customer Complaints & NCR data base.

Resolved customer complaints resulting in a $3 M per year cost savings by implementing design changes to several manufacturing quality Issues. Performed Lean Six Sigma Projects to improve Quality.

Performed Risk Management(FMEA) for Manufacturing equipment (Welding Machines, Powder Coating Equipment); made changes to Preventative and Proactive Predictive Maintenance schedules to improve productivity, quality and avoid unnecessary break downs.

Implemented Lean manufacturing tools (5S, Kaizen, Continuous Flow), improved process speed and achieved waste or scrap reduction from 6% to 1% ($1M savings).

Identified and eliminated process variations resulting in internal and external failures and lead improvements to reduce Cost of Quality, improve yield or customer satisfaction through 8-D corrective action, Six Sigma, LEAN tools and other QMS (Quality Management System) tools and processes.

Established controls and inspection points to facilitate detection, correction, and prevention of nonconforming materials, parts, assemblies, and products. Presented charts regarding product, process quality, Cost of Poor Quality (COPQ) and key Performance Indicators (KPI) on weekly basis.

Coordinated and provided required project quality related deliverables including FAT (Factory Acceptance Testing), PFMEA, capability studies, statistical analysis, inspection plans, quality records and workmanship standards.

Possess strong work experience in LEAN Tools (5s, Continuous Process Improvement Kaizen, Continuous Flow, KANBAN; KPI, OEE, Value Stream mapping TAKT Time, PDCA); Six Sigma Tools(FMEA, MSA, Control Charts, Pareto Charts, SPC, DOE, Process mapping, Process Capability Cpk, Ppk; Gaga R&R); 8D; DMAIC; GD&T, PFMEA; RPPM Reports; MRB (Waste Reduction & Control Techniques), Calibrating Instrument /Equipment per ISO17025-2005 Standards; measuring and testing equipment Faro Arm, CMM.

Performed customer plant visits to analyze customer issues with product quality. Worked investigations of field failures and liaison with Design Engineering, Manufacturing, Sales, Service and Customer.

Worked closely with Manufacturing, Engineering, Suppliers, Factory Operations, Sales and Supply Chain to facilitate resolution of technical problems.

Conducted internal audits (Process Quality, Procedures, Customer Focus Audits; Product QA), external (supplier) audits and served as Quality representative for customer on-site visits/audits.

Managed Quality Receiving Inspection group, generated Initial Inspection Reports (IIRs) and PPAPs (HQMS System) on received parts from vendors.

Manager (Project Quality, Manufacturing, Supplier Quality, Product, Process Quality, Metallurgy, ISO 9001, Customer Relations) June 1997 – August 2011

United Space Alliance (USA)/NASA, Houston, TX

Performed Risk Management Failure Modes and Effects Analysis (FMEA) for Space Shuttle hardware (Flow Control Valves, Metal Bellows Flex hoses, Pressure Vessels); launch support equipment (Pipelines, Storage tanks, Flow Liners, Boilers, Heat Exchangers, Mobile launch Plat forms, Crawlers); Rotatory equipment (Compressors, Pumps, Cooling Coil Modules) that helped SSP (Space Shuttle Program) to manage Program Risk to the Shuttle hardware and manage cost.

Provided Project Quality Assurance/Quality Control support to Engineering and Design teams during project execution. Performed specification reviews, development of the Project Quality Plan and Inspection & Test Plan (ITP).

Possess strong working knowledge in pressure vessel performance and inspection concepts (hydrostatic pressure tests, data books, engineering drawings and ASME Code (ASME “U”, NBIC “R”)

Possess strong work experience in 3rd Party Standards (ASME B&PVC Sections VIII and IX, ASME B31.3, B31.9; and ASTM).

Possess strong work experience in Fabrication Techniques (welding methods and procedures).

Possess strong working knowledge in NDE Methods (hardness, hydrostatic, liquid penetrant, magnetic particle, PMI, radiography, and ultrasonic examinations); and Documents (data sheets, engineering drawings, Inspection Reports, Inspection and Test Plans).

Confirmed compliance with the customer’s purchase order regarding the project and process requirements.

Supported specification and requisition development of major buy-out equipment items such as heat exchangers, pumps and compressors.

Developed Project Quality Plan, Inspection & Test Plan. Performed review of Project Job Manuals.

Performed Project Engineering support and participated in the upfront project proposal, planning, development, engineering and manufacturing processes, meeting operational objectives in Safety, Quality, Delivery and Cost.

Performed drawing/document review checklist to ensure engineering drawings and other design deliverables & datasheets were in compliance with project specifications. Performed shop visits of sub-vendors and traveled to the jobsite as needed.

Assisted in cost estimation by performing specification reviews, preparing summary list of requirements and acceptance criteria, identifying material, WPS/PQR, NDE requirements and requirements for coating and insulation.

Assisted in development of Design Input Checklist, review of engineering and drawing deliverables and preparation of Design Review Checklist and Drawing Review Checklist.

Worked as a lead for Root Cause Analysis(RCA); root cause corrective action methodology (Six Sigma/8D); CAPA; NCR; Corrective Action Plans (CAR) Preventive Action(PAR). Possess strong knowledge in Quality principles including NCRs, CARs, PARs, sampling techniques, and process control.

Reviewed customer material & manufacturing specifications and ensured that equipment design matched specifications.

Provided technical assistance to customers during project execution and field operations as required.

Developed and maintained Materials and Process Engineering (M&P) specifications of metallic materials, non- metallic materials, corrosion protective coatings, insulations, heat treating and Non-Destructive Evaluation (NDE) processes.

Performed several metallurgical analysis (materials selections, evaluations, testing of metals, non-metals insulations, and coatings), plastics, elastomers; welding inspections and repair (Per Welding Standards AWS D17.1), WPS, PQR's, Weld Logs; Failure Analysis; NDE inspections.

Possess working knowledge of assembly and welding processes and testing methods used to construct and certify pressure vessels and associated piping systems.

Possess strong working knowledge of material properties (chemical, mechanical properties) and certifications (NACE, PED) associated with steel plate, pipe, flanges, and fittings.

Liaison between the customer (NASA) and the contractors and suppliers; worked as the suppliers primary contact and performed several quality surveillance activities.

Quality Engineer June 1993 - June 1997

University of Texas Health Science Center, Houston

Responsibilities included performing research, developing protocols for drug companies, product development.

Manufacturing Quality Engineer (Process& Quality Control) April 1986 - June 1993

Chemicals Incorporated Baytown, TX

Primary responsibilities included focusing on maximizing production by reducing equipment failure and downtime, lowering maintenance costs, and minimizing safety/environmental concerns.

EDUCATION

MS (Chemistry-Metals & Polymers); BS (Mathematics, Physics & Chemistry) from Accredited Universities

CERTIFICATIONS AND PROFESSIONAL DEVELOPMENT ASSOCIATIONS

NMA-Project Management Professional (PMP) Preparation Series (16 hours)-May 2010

Advise for Successful Projects (Project Management Course) (8 hours)-April 2010

University of Houston, Leadership & Management Certification Program (36 hours) – July 2008

United Space Alliance, Integrated Project Management Program Certificate (24 hours) – June 2009

Completed the Leadership Training Programs at Boeing in St. Louis and United Space Alliance in Houston

United Space Alliance/Cadence Mgmt Corp, Project Management Certificate (16 hours) – November 2000

Metallurgy and Failure Analysis course offered by ASM International (40 hours)- April 2007

Fracture Mechanics, life assessment, and fracture control course (40 hours)- April 2007

NASA/Apollo Services, Root Cause Mapping Certificate – May 2010

San Jacinto College/Think Reliability, Cause Mapping: Effective Root Cause Analysis - August 2010

COMPUTER PROGRAMS AND SYSTEMS EXPERIENCE

Working knowledge of Microsoft Excel, Visio, Project, Word and Power Point; Linux; Unix Operating Systems; Minitab; Auto Cad (Creo); Finite Element Analysis Tool; Matlab; HQMS; SAP; BPCS (ERP system)



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