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Engineer Mechanical

Decatur, Illinois, United States
February 09, 2018

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Rakesh Gajula


Optimizer, certified Six Sigma Green Belt holder, Industrial/Mechanical Engineer and 3+ years of experience in engineering domain. Experienced & dexterous in discovering methods to crush the problems in processes. Efficient in tying together machines, materials, human resources, and information to extract profits.

Professional Experience:

Caterpillar Inc. Decatur, IL

Manufacturing Engineer (Contract) Jan 2018 – Present

Update MES, visual aids in Teamcenter Visualization Mockup and guide assemblers on complex operations.

Document the issues of quality, safety, velocity and cost metrics. Perform in-process validation and suggest & implement interim containment actions and permanent corrective actions.

Co-ordinate with supply chain & product layout departments on currents & future projects.

Analyze, solve and implement solutions to the workflow issues on the Large wheel loader-994,993 assembly line related to manufacturing, assembly, and safety.

Integra Technologies Houston, TX

Industrial Engineer Jul 2017 – Dec 2017

Created VSM, conducted time studies, determined non-value added steps, suggested kaizen events to reduce downtime by 10%.

Re-designed order pick path & rack layout in the warehouse to reduce average travel distance for order pickers by applying ABC analysis.

University of Houston- Keeland Design Center Houston, TX

Graduate assistant Aug 2015 – May 2017

Conducted weekly CAPA, 5S and maintenance review meetings for the closure of the red tags.

Expedited student’s check-in and check-out time to various facilities in the workshop by introducing QR scan codes in turn, saved man-hours. Revitalized the ergonomics of office area.

Implemented Mieruka to design user-friendly safety and warning systems.

Negotiated time and material contracts with vendors and listed them on basis of key parameters to meet fluctuating demand.

Trained students on skilled trades, Laser machine, and CNC machine and various gauges.

Ref Technologies Hyderabad, India

Manufacturing Engineer May 2014 – Jul 2015

Looked after the production operations of pre-fabricated cabins. Assign, coordinate and review portions of the work to support personnel, clients and suppliers.

Prioritized, prepared and controlled production Schedules, Bill of Material (BOM), Product Layouts for four manufacturing products.

Served as liaison between internal customers and management to ensure adequate inventory levels by tracking key inventory metrics and lead times using NetSuite.

Led continuous improvement events by collecting data and analyzing.

Time studies to avoid bottlenecks

Root cause analysis on underlying areas

Reduced search time using 5S

Conducted FMEA to reduce RGA’s

Organized monthly kaizen sessions

Implemented 8D; developed containment plans & corrective actions

Bharath Heavy Electricals Limited Hyderabad, India

Engineer Trainee May 2013 – Jul 2013

Part of Software installations and execution(IQ/OQ/PQ), Preparation, approval, and validation of entire SDLC document as per 21 CFR Part 11 guideline and execution of the system.

Played an active role in employee safety training and learned ISO 9001:2008, and OSHAS 18001:2007 standards.


Master’s in Industrial Engineering University of Houston Aug 2015 – May’2017

Bachelor’s in Mechanical Engineering JNTU, Hyderabad Sep’2010 – May’2014

Academic Projects:

University of Houston Houston, TX

Quality improvement in die casting of pinion housing

Executed DMAIC methodology to diminish the rejection rate in die casting of pinion housing.

Identified problem by analyzing data and pareto charts. Narrowed down the scope to focus on major issues.

Detected underlying aspects; applied various lean tools to figure root causes, methods to eradicate causes and stabilize process.

Reduced rejection rate from 8.13% to 5.18% which reduced overall material rejection by 2.5%.

Results: Scheduled dispatched fulfilled, saved $ 0.14million/yr. by cutting the rework operating costs.

Tools used: SIPOC, VSM, Pareto charts, Ishikawa, Cause validation tables, Prioritization matrix, NGT, JMP, MS Visio.

Reducing the cycle time of logged IT service tickets

Executed DMAIC methodology to cut down the cycle time in Integra Solutions an IT solutions company.

Walked through the entire process virtually by interviewing the employees from all levels of swim lane flow chart.

Applied various lean tools to determine the reason for lag in tickets by drilling down the potential causes.

Suggested few ideas and methods which led to decrease the cycle time from 18.52 to 15.3 minutes.

Tools used: SIPOC, Swim lane, MS VISIO, JMP, Fishbone, interviewing, Nominal Group Technique, Pareto charts.

Process optimization of pinion housing machining

Determined important dimensions in C346 pinion housing out of 60 dimensions.

Analyzed the trends in Xbar-S and CUSUM charts of belt face perpendicularity and box center to check the outliers.

Created cause and effect diagram to figure out the reasons for deviations from the measurement.

Suggested plans to avoid deviations and corrected control limits to comply with specification limits.

Tools used: Minitab 17, MS Visio, MS Excel, SPC


Six Sigma Green Belt

Rigging and Material Handling

Skills & Tools:

Tableau, MS Excel, Minitab 17, JMP, Auto CAD, MS Visio, SQL, NetSuite(ERP), MS Word, MS Outlook.

Lean Manufacturing, Kaizen, SPC, Continuous Improvement, Method and Time studies, Ergonomics, MES.

Root cause analysis, CAPA, 5S, Value Stream Mapping, VA/NVA analysis, Kaizen, Poka-yoke, 5Whys.

ANOVA Gage R&R, 8D, ISO 9001, Metrology, IQ/OQ/PQ, CNC, Die Casting, SOP, Fault tree analysis, NCR.

MRP, Bill of Materials (BOM), M.O.S.T, Kanban, Forecasting, Data analysis, FMEA, PFMEA, Fishbone, PLC.


Graduate Indian Student Organization Vice President Logistics May 2016 – May 2017

Developed and executed a plan for airport pick up and accommodations for around 300 international students studying at the University of Houston.

Projected annual logistics budget and in charge for procuring materials required for cultural events, bake sales for an approximate audience of 3000.

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