Engineer Lean Manufacturing

Srinivas Gidigu

**** ******* **, # *** ********, California 90503

Email: ********.******@*****.*** ; ********.******@*****.*** Phone: 248-***-****

Summary

Grew from a Trainee to Executive Engineer to becoming a Senior Executive Engineer at Siemens Limited in 5 years with hands-on experience in the following

Six Sigma

Quality Auditing

Lean Manufacturing tools

Problem solving methodologies (7QC and 8D)

Lean Quality Tools (FMEA, Pareto Charts, Fishbone Diagrams, 5S, 8D Methodology)

Geometric Dimensions and Tolerance (GD&T)

Value Stream Mapping (Present and Future)

ISO Compliance

APQP (PPAP, Control plans, FMEA)

Shop-floor Management

Process Development

Quality Function Deployment

Layout and cellular manufacturing

SPC, GD&T

Work History

Quality/Continuous improvement Engineer, June 2017 – present

Integra Technologies.

Review, update and implementation of QMS documents, procedures and work instruction. and establishing an effective operator controlled inspection methodology, that will cover; incoming material inspection, in process checks, and the documentation.

assisting with the root cause analysis/reduction and generation of 8D reports along with administration of an overall closed loop CAPA (Corrective Action & Preventive Action) system.

Drive Continuous Improvement activities in the facility. Assist in the coordination and training of facility LEAN initiatives while creating and providing structure and formality to LEAN implementation and supporting LEAN manufacturing philosophy.

Evaluates work flow and cell design, and recommends improvements to enhance productivity and safety.

Tracks and executes cost reduction on process improvements, Documents and communicates improvements in manufacturing overhead, efficiency and utilization.

Sr. Executive Engineer, Siemens. Jan 2015 - Aug 2015

Production Process Development /Quality

Lead a team to successfully implement the "SPS Expert Learning Program" where fellow employees received training and understanding of key concepts used in the Siemens production Systems (Lean Manufacturing: Reduce WIP maintain single piece flow, Visual management and communication)

Applying the concepts of Work Place Ergonomics to the environment and redesigning the process and cell layouts

Updating the Quality assurance plan for production, manufacturing flow diagram, test plans and documenting the change life cycle after SOP for the project.

Customer related complaint reviews, Co-ordination with all user departments for QA activities, validation of first samples as per specifications and documentation of the problems using A3,8D, corrective & Preventive actions(CAPA) for the future references.

Experience in minimizing holdups by maximum utilization of manpower, materials and machines to attain high productivity by planning uninterrupted flow of material from suppliers to assembly lines.

Ensuring examinations of machine, process and testing equipment capability based on Statistical evaluation and critical to Quality indicators

Executive Engineer, Siemens. July 2011 - Dec 2014

Production Process Development / Quality

Developing present and future state Value stream maps and identifying the area of improvements and executing the Value-added projects by considering the Return of Investments(ROI).

Collecting internal quality data from various stages of manufacturing to produce graphs charting data to demonstrate quality trends and evaluate alternatives to marginal mfg. processes, making recommendations as required.

Prepare, update and maintains the FMEA’s, SIPOC, process flow diagrams and process control plans critical in maintaining high quality standards of product and safety.

Preparation of Hazard Identification and Risk assessment(HIRA) chart and Aspect impact charts as per ISO 14001 and OSHAS 18001 standards

Studying process times as per the Maynard Operation Sequence Technique (MOST) and applying the process development ideas to reduce the throughput time of operations

Graduate Engineer Trainee, Siemens. June 2010 - Jun 2011 Production

Involvement in preparing and updating PFMEA and other quality documents, supplier/assembly audits,

Strong knowledge of PPAP, PFMEA, Control Plans, MSA, GR&R, Capability Studies.

Improvement or quality issues Communications with suppliers on products and process concerns by working closely with cross functional team to solve problems and continuously improve output.

Develop and maintain Quality control documents and implement QC tooling and inspection process flow. Ensuring manufacturing documentations are up to date and maintain a current Plant Layout which matches the floor and supports strike zone workstations.

Conducts investigations on non-conformance and recommends corrective action to prevent reoccurrence, with formal written documentation, recording the incidences for future reference and training.

Projects/Achievements

Lean transformation of factory Successful implementation of Lean concepts at various levels of operations in plant level

●56% reduction in transportation distance of material.

●18% increase in the space productivity.

●28% increase in the product revenue per square feet.

Improving customer satisfaction by curtailing the number of customer complaints.

●48% reduction of customer complaints from project sites.

●An active team player in structured way of problem solving using 7 QC tools for a customer complaint, which won a global appreciation from Siemens AG

●Active team player in driving zero defect culture in the plant level.

Technical skills

Software: AutoCAD, PRO-E, CATIA, SolidWorks, Workspace

Analytical Tool: Minitab, DOE, MODAPT

Quality Management System: ISO 9001:2009, TS 16949-2002, GD&T, QS:9000

SAP: PP Module

Tools: MS-Office

Certification: Six Sigma Green Belt, Fanuc Robot handling and programming

Education

Wayne State University Detroit, Michigan, Aug 2015 - May 2017

Masters in Manufacturing Engineering, GPA 3.5

Jawaharlal Nehru Technological University Hyderabad, India, June 2009

Bachelors of Technology in Mechanical engineering, GPA 3.8

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