Engineering Lean Manufacturing

Rahul Kulkarni

**** ******* *****, *** ****, Dearborn, MI - 48126 • Email: ********@*****.*** • Mobile: 313-***-**** OBJECTIVE

To work in a challenging career where I can apply my technical knowledge along with my creativity and perseverance while benefiting my employer.

EDUCATION

UNIVERSITY OF MICHIGAN – DEARBORN Dearborn, MI

Master of Science in Engineering, Industrial and Systems Engineering May 2017 Relevant Core Courses:

• Production and Operations Management • Total Quality Management & Six Sigma • Systems Engineering

• Human Factors and Ergonomics • Enterprise Information Systems • Project Management

• Supply Chain & Logistics • Design of Experiments • Optimization OSMANIA UNIVERSITY Hyderabad, India

Bachelor of Engineering, Mechanical Engineering May 2015 PUBLICATION

• Kulkarni Rahul, Dr.S. Gajanana, Tharun Vempati, Shreyas Gampa and JV Srinath. "Production & Process Optimization of Micro-Alloyed Steel Roller Shaft of an Under Carriage" International Journal of Engineering Research 4.7(2015)

PROFESSIONAL EXPERIENCE

9th Annual Ergonomics Design Competition by Auburn Engineers Dearborn, Michigan Academic Project Fall 2015

• Identified and evaluated the major ergonomic risks involved in the tasks performed by workers at animal shelter using 3D Digital Human Modelling/ Simulation by Siemens – Jack

• Selected each assessment tool according to the body region affected: Moore Strain index

• Simulated the process in Jack by adding the real-life conditions, and then performing analysis of several ergonomic aspects like RULA and REBA

• Identified and resolved ergonomic issues during the physical builds, lead identification and assessment according to the ergonomic standards NIOSH lifting guidelines, Trustmark and OSHA standards Fabrication and process optimization of micro alloyed steel roller shaft on CNC vertical milling center Berco Undercarriages PVT.LTD. Academic Thesis Project September 2014 – May 2015

• Constructed and monitored all facets of production including fabrication, operation of design and manufacturing

• Created assembly drawings, including bill of materials and detail drawings, for machining, assembly and welding

• Implemented design of experiments(DOE) process to improve process efficiencies and optimize the output parameters

• Developed a regression model for Material removal rate(MRR) and surface roughness using full factorial DOE

• Tested the adequacy of the model by fisher test at 5% significance level

• Contribution of each input factor (along with their interaction) on output is determined by Analysis of Variance

(ANOVA) and using MATLAB software, the optimum input parameters values for Metal Removal Rate and Surface Roughness were obtained

Vehicle speed control based on GPS/MAP matching of posted speeds Dearborn, Michigan Academic Project Winter 2016

• A mechanism which automatically adjusts the vehicle speed in accordance with the road being used at any given instant by using the posted road speed data available in GPS database

• Analysis of the subject system using DFMEA process Lean Management of Kitchen Production in a Salad Company Grand Rapids, Michigan Saladworks Fall 2015

• Created a Value Stream Mapping of the current and future state of the specific actions

• Implemented Kaizen and 5s principles

• Eliminated functional barriers which dramatically increased lead time

• Also, optimized various parameters which resulted in reduction of wastes and over production Quality Function Deployment (QFD): Customer Needs, Benchmarking and Development of Interior Package Targets Academic Project Dearborn, Michigan – Winter 2016

• Application of the Quality Function Deployment technique by applying it to interior chunk of Steering wheel, pedal, seat for Honda Accord.

• Determine the customer needs for the “chunk” in the interior package

• Relate the customer needs to relevant package specifications

• Benchmark the same chunks in BMW 3 series and Volkswagen CC

• Determine important design variables for the selected “chunk” in interior package

• Determine design targets for the selected “chunk” in interior package SAE India Efficycle, Chennai &Punjab, India. June 2014

• Worked on the design and fabrication of an energy efficient eco-friendly vehicle for performance and reliability

• Provided an innovative design to tackle engineering problems and manufacturability of the vehicle

• Designed the frame and suspension systems for the hybrid vehicle that is aerodynamic and ergonomically stable Hindustan Petroleum Corporation Limited (HPCL) Mangalore, India Intern Summer 2014

• Observing various methods involved in storage of petrol and HSD in underground tanks

• Various aspects of distribution and marketing of Petroleum products with reference to Petrol, High Speed Diesel

(HSD), and lubricants for automotive market

Research Centre Imarat, Defense Research and Development Organization (DRDO) Hyderabad, India Intern Summer 2013

• Designed innovative component replacements for existing machinery to improve functioning and minimize costs

• Evaluated product data and design by completing technical studies for ISO, DFM and preparing cost estimates

• Assisted in improving and refining processes to enhance lean manufacturing approach for new products

• Implemented flow manufacturing and 5S methodology to organize workspace for efficiency

• Performed regular performance reviews with suppliers and worked on product improvement

• Assisted with project specifications by studying product design, requirements and performance standards ACHIEVEMENTS & EXTRA CURRICULARS

• Currently working as ACADEMIC SERVICES ASSISTANT in College of Arts, Science & Letters at University of Michigan- Dearborn

• Founding Member & Managing Editor of Human Factors and Ergonomics Society (HFES) – Dearborn Chapter

• Recipient, Non – Resident Graduate Student Scholarship (merit based scholarship)

• Team member & CAPTAIN of team “CYCLOTRON” which represented MVSREC in the SAE-EFFI-CYCLE 2014

• Member of the student body, MVSR Campus Connect, organized and volunteered at the annual technical and cultural festivals and Headed Campus Communications which is responsible for all the communication between the faculty, staff and students

SKILLS

Technical skills: MS Office, SolidWorks, AutoCAD, Pro/e, CATIA, ANSYS, MATLAB, Mastercam Machining skills: CNCs, Welding, Milling, Turning, Drilling, Grinding, Sheet metal forming Others: Lean manufacturing, Six sigma, Kaizen techniques, PFMEA, DMAIC

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