SHIVA KIRAN MADALA

269-***-**** • ac1da8@r.postjobfree.com

OBJECTIVE

Seeking for full time position as a Quality Engineer, where my resourceful experience and academic skills will add value to organizational operations.

SUMMARY

Diverse background in Manufacturing, Operations, Process improvement and Quality.

Well proven expertise in international standards, six sigma applications, tools and techniques employing Lean manufacturing.

Experience with SolidWorks, AutoCAD and acquaintance with CATIA V5.

Intermediate knowledge in understanding GD&T and interpreting Blue prints and ISO 9001, ISO/TS-16949, standards.

Adequate knowledge in Statistical Process Control (SPC) and performing Process Capability Study using Minitab.

Knowledge of APQP, PPAP, manufacturing Processes, quality control and testing.

Certified Six Sigma Green Belt.

Participated in Creating, reviewing and approving Design Failure Modes and Effects Analysis (DFMEA).

Key areas of experience include Quality, Data Analysis, Project Management.

SKILLS

Minitab, Rapidminer, Promodel, Auto CAD, SolidWorks, CATIA V5, Lean Manufacturing, Kaizen, 5S, SMED, Gage R&R,

GD&T, PPAP, APQP, Quality tools, Root cause Analysis, 8D, Failure Mode Analysis, New Product Development.

ACADEMICS

Master of Science in Industrial Engineering (Western Michigan University) GPA (3.25) April 2017

Relevant Courses: Design of Experiments, Capital Budgeting and Cost Analysis, Production/Operations Management, Simulation Modeling and Analysis, Supply Chain Management, Ergonomics, Applied Data Mining, Continuous Improvement in Operations, Six sigma, Project Management.

Bachelor of Engineering in Mechanical Engineering (Vignan’s University) GPA (3.5) May 2014

Relevant Courses: Material Science & Metallurgy, Finite Element Analysis, Fluid Mechanics & Hydraulic Machines, Dynamics of Machines, Design of Machine Elements, Production Technology, Manufacturing Engineering.

WORK EXPERIENCE

Tough Team Plastic & Manufacturing, Guntur, India. June 2014 – July 2015

Process Quality Engineer

Performed root cause analysis for all customer complaints and audit non-conformances and led subsequent corrective action response, implementation and verification of those countermeasures.

Supported manufacturing engineering team for new product development and process improvement and to reduce customer complaints by using Design of Experiment (DOE) and Data Analysis.

Collaborated with cross functional team for process improvement. Troubleshoot problems encountered with equipment and manufacturing process.

Led and facilitated process improvement teams with Lean tools such as Pareto charts, process flow charts, Value Stream Mapping and basic statistics. Reduced overall lead time by 20%.

Analyzed Customer Issues through 8D / 5-Why approach and generated R&M reports collaboratively implemented Corrective and Preventive actions.

Planned and Organized Kaizen Events and Work towards Continuous Improvement through Motivation and Creation of Platform for Innovation and Root Cause Analysis for defective parts.

Performed inspection of Raw materials, materials in process and finished goods for quality assurance.

Ensured customer satisfaction by conducting weekly meetings with clients to provide status and detailed analysis on the expected metrics.

Performed Measurement System Analysis (Gage R&R) for PPAP documentation.

Implemented Six Sigma methodologies, Design of Experiments, risk assessment, process FMEA, cause and effect studies to successfully troubleshoot factory failures and field returns.

Managed and coordinated the APQP and PPAP documents for new product launch approvals for client base on as needed basis. Utilized quality tools, PDCA and standardized work instructions to reduce material costs. Responsible for new product Introduction(NPI).

Hindustan Shipyard Limited, Vishakhapatnam, India. January 2014 – May 2014

Intern as Industrial Quality Engineer

Assisted quality department in preparation of customer audits and participated in some professional meetings.

Ensured compliance with Built in Quality and ISO standards.

Supported Quality engineers in GD&T testing to eliminate any kind variations in the assembly process for shipbuilding and submarine assembly process.

Oversaw Shipyard Quality control, NDT testing for assembly, Structural and piping system. Performed weld Inspections and Non-Destructive Examination.

Coordinated Mechanical engineer in reviewing and approving engineering design changes in the assembly process and make necessary changes.

Kumar Pumps, India JULY 2013 – DEC 2013

Manufacturing Engineer Intern

Improved manufacturing capabilities by training employees for their job to ensure maximum productivity.

Trained in Process Capability, BOM, Mistake Proofing, FMEA, DFMEA, Six-Sigma Analysis and ISO Standards.

Presented project update and process capability analysis to senior management.

Generated various engineering documents such as work orders and accordingly made changes to the process.

Tracked defects for various parts in the manufacturing process.

Coordinated with engineering department by updating Recorded defects and issues report.

ACADEMIC PROJECTS

GM1381 (Cadillac, CTS 4 Air Filter) - MANN+HUMMEL, Kalamazoo, MI December 2016

Investigation of GM1381, the high rejection rate of the airbox during the end control process.

GM1381 Air Box experiences of a high scrap rate with 75% of the airboxes manufactured undergoing quality rejections, which results in high manufacturing costs driving higher sales prices.

Analyzed manufacturing process data to recognize a premature failure. To anticipate the failure/rejection before moving the sub-assembly to the next station.

Conducted hypothesis test for Manufacturing Tolerance stack and weather data.

Rapidminer software used for data mining.

Catapult, War Prototype - Design of Experiments June 2016

Manually built catapult to test various factors that affect the distance travelled by the ball released from the catapult.

Investigated best combination of factors that result in maximal projectile achieved by ball was found by using design of experiments (DOE).

Analyzed cause and effect relationships by varying input factors.

Implementing Lean and six sigma techniques in a pipe manufacturing plant – Continuous Improvement May 2016

Production rate increased up to three times than before with almost no extra cost by using lean and six sigma techniques.

Reduction of complaints from customers as quality control enhanced.

Overall production lead time of the pipes reduced from 12.5 days to 7.3 days which was forty two percent by using value stream mapping (VSM).

Machine idle time decreased by implementing continuous production instead of batch production.

Impact on Lumbar Disc while lifting weights in different positions – Ergonomics December 2015

Investigation into methods of developing ergonomic guidelines for manual material handling plant for musculoskeletal disorders, leading causes of occupational injury and disability in the United States.

Evaluation of shear and compression forces and to know the risks involved in lifting weights on the lumbar disk. 3DSSPP was used to find the percentage of population affected in different situations.

NIOSH guidelines, OSHA standards, and RULA sheet used for determining better positions.

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