Quality Engineer Six Sigma

Sai-Teja Ghanta

Email: ***.****.******@*****.***

www.linkedin.com/in/saitejaghanta

Phone: 312-***-****

EDUCATION

Wayne State University College of Engineering, Detroit, Michigan May 2017

• Master of Science in Industrial Engineering * Grade Point Average: 3.6

Six Sigma Green Belt, 2016

GitamUniversity, Visakhapatnam, Andhra Pradesh, India May 2015

• Bachelor of Technology in Mechanical Engineering * Grade Point Average: 3.2 SUMMARY

Six Sigma Green Belt offering two years of experience in quality engineering, lean manufacturing techniques and product/process improvements.

Deliver quality controls and enhancements to proactively address quality problems and improve product quality, manufacturing flow, customer satisfaction and bottom line results.

Six Sigma Tools – DMAIC Methodolgy

Lean Quality Tools – FMEA, Ishikawa

diagram, 8D Problem solving

APQP & PPAP Expertise

SPC & Capability Studies for CpK, PpK

Software – MiniTab, AutoCAD

Value Stream Mapping

Geometric Dimensioning &

Tolearancing (GD&T)

Design of Experiments (DOE)

Gage R&R

EXPERIENCE HIGHLIGHTS

Quality Engineer, Kusalava International Pvt Ltd, Vijayawada, India April 2014 – August 2015

Core member of the quality team in the manufacturing of cylinder liners, piston, piston rings and successful documentation and implementation of PPAP and APQP requirements.

Utilized statistical methods such as Process CapabilityData Analysis (PCDA), Statistical Process Control

(SPC) to improve process capability and reliability by 20%, resulting in scrap reduction by 25% and reduced cost of poor Quality (COPQ) by 15%.

Identified the significant control factors and their effect on process by performing design of experiments (DOE) to support process optimization yielding reduced cycle time by 35%, thus improving the process efficiency by 22%.

Supported in implementing lean manufacturing processes such as 5S, Kanban & Poka-Yoke.

Initiated, tracked and facilitated the closure of corrective and preventive action plans using 8D technique and performing root cause analysis.

Responsible for the process failure mode and effect analysis (PFMEA) investigations directed at a specific operational and throughput improvements.

Assisted in developing internal measurement gage R&R in support of required technical proficiency studies.

Examined the control plans to ensure that process requirements and expectations were visible to all the functioning areas.

Project Trainee, Kusalava International Ltd, Vijayawada, India April 2013 – August 2013

Consulted as part of a cross functional team, with the chief engineers of Design, Production as well as Quality departments and laid out the strategy to handle the delay in production at the casting process.

Identified the control factors by implementing the Fish-Bone diagram and determined the stability of processes using Control Charts.

Performed the keen operation analysis using DMAIC (Six Sigma Tool) technique that are ripe for cost and cycle time reduction.

Statistical Analysis is being performed using MiniTab to draw X-bar, R-Charts for variables, P-Chart and NP-Chart for characteristic attributes.

Process Improvement Intern, Ramadas Paper Boards Pvt Ltd, India April 2012 – July 2012

Identified and brainstormed reasons for variation in order delivery time for 600 customer orders and recorded their probabilities of occurrence.

Performed Root cause analysis (RCA) through 5 Why’s and Ishikawa diagram to determine the potential causes of variation, focused on ‘Vital Few’ causes and eliminated them. PROJECTS

Six Sigma Project: Maintain the inner diameter of the cylindrical liner to a single grade using DMAIC Process

Identified the manufacturing process stage, where the problem is generated due to input variation

(Final Honing).

Performed Data Collection & Analysis using Pareto Chart, 5K Process Map, Cause & Effect Matrix to identify and list the final suspected sources of variation.

Performed Measurement System Analysis (MSA) for relevant gauges and got it accepted. Identified the KPIV’s after conducting Process Search & Product Process Search using Root Cause Analysis.

Adjusted the KPIV’s such that the final inner diameter is within the specification and amended Control Plans for the final honing operation.

Fruitfully, reduced the internal rejections due to inner diameter variation, from 8000 PPM to 500 PPM, thus reducing cost by 80%.

Lean Project: Continuous Flow Manufacturing

Team Lead, took initiative and lead the team in the project process.

Initially studied the Plant layout and the manufacturing process, defined the KPI’s. Performed 5 Why’s and defined the problem statement.

Constructed a current state Value Stream Mapping (VSM) of the company.

Focused on filing and packaging. Performed real time observations and collected data of cycle times at various steps of the filling and packaging process.

Identified the bottle necks in terms of filling time and movement of packages. Identified wastes in terms of idle times of the filling operator.

Quantified the wastes in terms of cost, implemented lean tools for continuous improvement and generated a future state VSM.

RELEVANT COURSEWORK

Master’s – Six Sigma, Lean Manufacturing, Supply Chain Management, Operations Research, Production Systems, Quality Management Systems, Project Management.

Bachelor’s - Modern Manufacturing Methods, Production Planning & Control, CAD, Finite Element Analysis, Design of Experiments, Engineering Economics.

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