Quality Engineer Engineering

ABHISHEK ANANDA

***** ********* ***, ***. *** 224-***-****, ac2a09@r.postjobfree.com

South Gate, Michigan 48195 https://www.linkedin.com/in/abhishekananda PROFESSIONAL SUMMARY

• Quality Engineer with 2 years of experience and expertise in Root Cause Analysis (5 Why, 8D), FMEAs, MSA, Gage R&R, SPC, PPAP, PFD, PFMEA, SNCR, CAPA and Control Plans.

• Successfully managed a 22-person team in the inspection of safety critical components for FORD, GM, Volkswagen and demonstrated ability in improving production quality and reducing defects by 20%.

• Experience working directly with Customers, Suppliers and Sorters in the fast-paced automotive sector and experience with Quality Planning, Production Scheduling, Internal Audits, Supplier Audits, External Audits (TS16949, BIQS, VDA, Q1).

• Experience in managing cross functional teams globally with supplier bases in China, Portugal and India to ensure that castings are conforming to specifications and timings. TECHINICAL SKILLS & SOFTWARES

WORK EXPERIENCE

Quality Engineer November 2016 - Present

Sakthi Automotive Group USA Detroit, Michigan

• Trained and supervised 18 quality inspectors and 4 engineers for Final Inspection (GP-12), Safe Launch and In-Process Inspection Control (IPIC) for steering knuckles, axles, brackets and achieved significant improvements in their productivity.

• Review the documentation of Inspection and lead fast response meeting for countermeasure of daily quality problems.

• Perform First Time Quality (FTQ) using hand gages, functional gages, vernier calipers, micrometers, surface roughness tester, and bore dial for steering knuckles, axles and brackets.

• Read and interpret CMM reports, engineering drawings and the GD&T associated with the drawing to ensure part conformance and to clear the suspect parts on hold.

• Prepare I-Charts, Pareto Charts and Trend Charts to analyze the non-conformance and PPM performance of the products.

• Lead the cross functional team to defining final inspection, safe launch activities and responsible to create work instructions or Quality Alerts for Final Inspection, Safe launch, In-Process Inspection Control (IPIC) and ensured correct implementation.

• Address customer complaints (PRR’s) by initiating action plans, implementing interim containment actions and permanent preventive actions by applying 8D, fish bone and 5 why techniques.

• Raise CAPA (Internal and Customer) during the Material Review Board (MRB) meetings and form a cross functional team to work closely with with production, advanced manufacturing and MP&L teams in finding the root cause for the issues.

• Core member of the cross functional team for compiling PPAP package, developing APQP, PFMEA, PFD, Control Plans, MSA for current programs and documentation experience with different audits like ISO, BIQS, Q1, VDA, TS 16949.

• Conduct gage R&R for both attribute and continuous/variable data, analyzed results and applied lean principles on the shop floor to reduce various forms of wastes (Excessive time/motion).

• Work closely with the Director of Quality on estimating the Cost of Poor Quality (COPQ) and continuous improvement of the existing processes.

• Conduct Layered Process Audits (LPA) from receiving raw materials to final inspections to improve quality, reduce scrap, rework and customer rejections.

Continuous Improvement Projects

• Initiated suspect clearance and rework plan to convert the dead inventory into finished goods and saved $800,000.

• Implemented check sheets for shift engineers to check the critical parameters thereby reducing scrap by 20%.

• Designed and implemented trolley system replacing WIP dunnage to easily detect the parts with non-conformances.

• Introduced red tag concept to prevent the escape of setup parts to finished goods, introduced color coded internal labels to prevent part mix up and line wise printer to avoid mislabeling of parts. Quality Engineer July 2013 - July 2014

Madhu Fabs Private Limited Bangalore, India

• Prepared quality inspection instructions, managed quality issues, identified root cause and implemented corrective actions.

• Performed product quality audits for storage tanks, hoppers and hand railings to reduce human errors and non-conformities.

• Visit customers and suppliers as required to investigate non-conformance issues and provided support to purchasing team for evaluation and qualification of new suppliers or continuous improvement activities of existing suppliers.

• Developed and implemented standard methods and procedures for rework and disposition of nonconforming material.

• Maintained accurate quality and manufacturing records such as updated engineering sketches, engineering change requests, work instructions, supplier part specifications, FMEA’s, control plans and internal test results.

• SPC • PFD • PPAP • SolidWorks 2015 • CATIA V5

• MSA • SNCR • APQP • AutoCAD • PTC Creo

• GAGE R&R • CAPA • Minitab • Unigraphics NX 9.0 • ANSYS R 16.2 ACADEMIC PROJECTS

Design and Finite Element Analysis of a Spur Gear August 2015 - December 2015

• Designed an equation driven spur gear with perfect involute in SolidWorks 2015 by following the American Gear Manufacturers Association (AGMA) standards.

• Imported the spur gear into ANSYS and conducted Finite Element Analysis to determine the maximum bending stress.

• The maximum bending stress was analytically calculated using Lewis Factor equation and achieved a very good correlation with Finite Element Analysis results. (0.2% error).

• Gained understanding of 3D modeling, Finite Element Analysis software, designing load cases and correlation. Design and Analysis of a Self-Centering Machine vice January 2015 - May 2015

• Designed a self-centering machine vice using SolidWorks 2015 which could automatically adjust the work piece positioning and clamping it precisely and quickly on a defined symmetrical axis.

• Conducted kinematic and dynamic motion analysis to evaluate forces generated by the system.

• Performed static and dynamic Finite Element Analysis on the jaw of the machine vice for different loading conditions to determine displacements, stresses, strains and reaction forces under the effect of applied loads. Design of a Gear Drive with a Cam January 2015 – May 2015

• Designed a gear drive using SolidWorks 2015 to transmit motion and torque which comprised of a pair of gear and pinion connected to the Cam.

• The Cam was designed using the equation driven method where in the size was dependent on the diameter of the shaft used and thickness was an arbitrary value.

• Gear-1 drives Pinion-1 which in turn drives the Gear-2 and Gear-2 drives Pinion-2 and Pinion-2 drives the Cam. Design and Analysis of tilting mechanism for testing of motors January 2013 – May 2013

• Designed a special purpose mechanical lift, tilt and turning mechanism on CATIA V5 using a gear train and tilting table to lift and tilt (360 ) a servo motor weighing 550lbs – 600lbs to a pre-determined height with size, stress and weight constraints.

• Finite Element Analysis was conducted on the tilting mechanism to calculate the bending stress, strains and deflections.

• Implementation of this special purpose mechanism for testing of motors at the company (Name Confidential) replaced the manual mechanism of using cranes for testing, cut short the testing time from 45 minutes to 15 minutes and minimized the use of skilled labor from 10 laborers to 3 laborers. INTERNSHIPS & TRAINING

Engineering Intern July 2012 - August 2012

South India Wire Products Private Limited Bangalore, India

• Read and interpreted blueprints and engineering drawings to ensure conformance of geometry, dimensions, tolerances, material and finish of mechanical products such as threaded rods, steel bars, automotive washers and fasteners

• Collaborated with engineers and engineering managers to optimize the safety Standard Operating Procedures.

• Systematically investigated system failures to resolve equipment malfunctions using Root Cause Analysis (RCA). Engineering Trainee January 2012 - February 2012

Gedee Automobile Training Institute Chennai, India

• Trained in the current trends of automotive service procedures and acquired working knowledge of steering, suspension, braking systems and fuel injection systems such as multi-cylinder fuel pumps, common-rail injection systems & fuel injectors

• In depth study about the working principles of heavy duty engines and engine performance by dismantling and assembling various types of Gasoline and Diesel Engines.

• Studied vehicle safety systems like ABS and ESP and trained on trouble shooting of CRDe, CRDi, MPFI and DTSi engines. Engineering Intern January 2011 - February 2011

Turbo Technic Private Limited Bangalore, India

• Actively involved in the design of different parts of turbocharger such as turbine, compressor and rotating assembly.

• Acquired knowledge on various types of tests such as containment test, start-stop test and LCF test which is used to determine the performance characteristics of the turbocharger.

• Performed sand blasting operation on turbochargers to remove the deposition from flue gases, grease, oil, scale and other impurities.

EDUCATION

• University of Illinois at Chicago August 2014 - May 2016 Master of Science in Mechanical Engineering GPA: 3.5

• School of Engineering and Technology, Jain University August 2009 - July 2013 Bachelor of Mechanical Engineering GPA: 3.7

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