Lean Manufacturing Engineer

SUMMARY

Manufacturing Engineer with *+ years of experience and academic background in Lean Manufacturing, New Product Introduction, Quality Systems, Statistical Analysis, Capital Budgeting and Project Management.

Passion for bringing new products into manufacturing, implementing Lean Manufacturing and Six Sigma techniques to resolve manufacturing issues, improve efficiency and yield, reduce cost and cycle time.

Working knowledge of BOMs, Engineering Change Orders and Configuration Management.

Develop Tooling and Fixture Design and Create Assembly Drawings.

Develop Specifications, Standard Operating Methods and Procedures.

Experience with DFx, GD&T, DOE, ANOVA, SPC, FMEA, Root Cause Analysis, CAPA, DMAIC methods and tools.

Working Knowledge of ROI and IRR analysis, Gantt Charts, CPM analysis, and Risk Mapping.

EDUCATION

Master of Science in Industrial Engineering Sep 2014- Dec 2016

Major: Industrial Engineering GPA: 3.50

Western Michigan University, Kalamazoo, MI

Bachelor of Engineering in Mechanical Engineering Jul 2010 – Jun 2014

Major: Mechanical Engineering GPA: 3.40

Osmania University, Hyderabad, India

CERTIFICATIONS

Certified Associate in Project Management (CAPM) Jan 2017 – Jan 2022

Project Management Institute (PMI), Newtown Square, PA License No. 2006609

Certified Six Sigma Green Belt (CSSGB) Feb 2017

Management and Strategy Institute (MSI), Downingtown, PA License No. 7330798

Certified SOLIDWORKS Associate (CSWA) Feb 2017

Dassault Systèmes SolidWorks Corp. License No. C-29TZRC3FBV

SKILLS

Software Tools: ProModel, Minitab, Oracle Crystal Ball, Excel VBA, Visio, Access, SolidWorks, ANSYS, AutoCAD.

Lean Manufacturing Tools: VSM, 5S, Kaizen, JIT, Kanban, Poke Yoke, Gemba, Jidoka, SMED.

Quality/Six Sigma Tools: DFx, DMAIC, RCA, DOE, ANOVA, FMEA, SPC, 8D, PDCA, CAPA, GR&R, Pareto Analysis.

EXPERIENCE

Student Employee Western Michigan University, Kalamazoo, MI Nov 2014 – Dec 2016

Assisted in effective implementation of 5S for an organized work environment for efficiency and effectiveness.

Contributed in overall facility operation and reduce lead time by 35% through efficient value stream mapping.

Improved the efficiency of inventory management and reduce the holding costs by 26% using principles of Kanban integrated with the principles of JIT.

Intern – Production Quality Engineer Vizag Steel Plant, Visakhapatnam Apr 2013 – Mar 2014

Analyzed hot steel samples for process quality using Optical Emission Spectrometer (OES) and slag samples to examine and suggest the blow pattern in the converter using X-Ray Fluorescence spectrometer (XRF).

Developed process flow chart and conducted VSM analyses to capture sinter operations.

Modified the sinter plant cell layout design using AutoCAD 2D drawing software and assisted in implementing the modified layout.

Line balanced the sintering process mixing lines and reduced the generation of sinter scrap from 17% to 5%.

Performed regular process inspections using SPC and statistical sampling to fulfill CTQ’s of customer.

Conducted GD&T reviews and DFMEA to identify any potential manufacturing defects in steel bars.

Reverse engineered fixture for assembly process adhering to GD&T standards, reducing cycle times by 20%.

Used root cause analysis and PFMEA to identify and resolve the problems at steel melting shop.

Junior Manufacturing Engineer Himajal Beverages Pvt. Ltd., Hyderabad Jan 2012 – Feb 2013

Implemented various lean principles like VSM, OWMM, Kanban and reduced the overall lead time by 6.3%.

Modified and updated floor plan blueprints, facility plans and layout drawings using AutoCAD.

Performed ROI analysis and capacity modeling analysis on types of feeding systems and increased the production rate by 18%, by assisting in replacing manual feeding system with an automated one.

Developed and implemented process control charts to monitor the feeding progress at regular intervals.

Implemented pull system of production, reducing process time by 1.5 mins and inventory levels by 45%.

Responsible for ensuring that molds and tooling were built to be production ready.

ACADEMIC PROJECTS

Simulation on Inventory and Machine Layout Redesign

Welch Packaging Elkhart Inc.

Modeled Welch packaging plant layout in ProModel to simulate various ongoing machining operations and overall production flow in the plant.

Total manufacturing cycle time of each product was captured by performing time and motion study analysis.

Performing statistical data analysis utilizing statistical software (Minitab and Excel).

Used CPM and VSM techniques to optimize forklift vehicle path and increase overall throughput by 14%.

Capital Budgeting Simulation

Generated a simulation model to evaluate multiple capital projects under various ranking criteria such as Net Cash, NPV, Payback, IRR, AW, NPV/FC, and AW/FC in Excel VBA.

Developed a regression model to analyze each method for profit optimization using Minitab.

Application of DFMA techniques to optimize air humidifier design

Analyzed air humidifier design from General Aire with an assembly efficiency of 9.2%.

Modelled air humidifier components using SolidWorks 3D modeling and created the Bill of Materials (BOM).

Reduced the design complexity and unit manufacturing cost from $74.65 to $19.94 by applying DFMA techniques without compromising structural integrity.

Replaced the design parts by using snap fits instead of screws and integrated some parts with base product and improved the assembly efficiency to 55.8%.

Ergonomics Project: Effect of EMG activity of selected abdominal trunk stabilizing muscles

Accurately defined ergonomic factors and associated levels to determine the effects on selected abdominal muscles while performing crunches on different exercise equipment.

Effect on the muscles was observed by conducting EMG analysis and performed regression analysis on the collected EMG data.

Conducted RULA & REBA assessments while performing tasks to identify the significant risks of MSDs and lower back injuries.

Design of Experiments and Factorial Analysis to determine factors Influencing Battery Life of Smartphone

Conducted full factorial DOE and developed a regression model to analyze the factors affecting the smartphones battery life using Minitab.

Used root cause analysis (Fishbone diagram) to find the factors that influence the battery life.

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