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Quality Engineer

Hayward, California, United States
February 13, 2018

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Hayward, CA ***** (510) ***-****


An Industrial Engineer expertise in conceptualization, creation, development and demonstration of innovative mechanical and manufacturing designs. Having industrial experience in Industrial Operations, Product Development, Production Planning and Control, Program Management, Manufacturing procedures and Quality Practices like Lean Six Sigma, Continuous Process Improvement, SPC, DMAIC principles, Kaizen, FMEA techniques. Collaborates with teams from engineering, planning and design to meet key project deliverables. Experienced in Project Management; able to communicate at all levels. EDUCATION

Master’s in Engineering/Industrial Management California State University, East Bay Hayward, CA 12/2016 Bachelor’s in Mechanical Engineering Anna University Chennai, India 05/2013 TECHNICAL SKILLS

Quality Tools: Minitab, 5Whys, Root Cause Analysis, DMAIC, DFMEA, PFMEA, Poka-Yoke Engineering Software: ProModel, AutoCAD, MATLAB, CATIA Microsoft Office: Word, Excel, PowerPoint, Project Keywords: Lean Six-Sigma Process, Lean Manufacturing Processes, GMP, ISO/TS 16949, 5S Kaizen, CAPA, SPC, Control Charts, Fishbone Diagram, Value Stream Mapping, 8D, NPI, DFM/DFT CERTIFICATION

Lean Six Sigma Green Belt 03/2017

Certified Auto CAD User 01/2010


Process Engineer, Manufacturing & Quality Sakthi Automotive Group USA Detroit, MI 06/2017 – Present

• Monitor all customer related quality concerns, including root cause analysis and resolution

• Prepared SOPs, quality alerts, 8D analysis, MTTR & MTBF reports

• Reduced value in scrap by improving the manufacturing process and cost

• Enhanced time studies and analyze downtime of process by performing root cause analysis on variation in process and implement Continuous improvement activities

• Performed a Preventative & Predictive Maintenance program based on historical data

• Maintained track of Inventory management, materials planning, needed calibration and spare parts documentation

• Generated and managed control plans, PFMEA’s, QC documentations such as quality & production manuals, procedures & standards for all production and prototype programs

• Incorporated 5s and Six-Sigma methodologies to solve design and manufacturing problems

• Participated in multiple internal/external audits for the purpose of improving both internal and supplier process

• Assured conformance to quality requirements are met with Layer Process Audit

• Performed first article inspections, PPAP’s, rework on defective parts & special components tests

• Assisted quality managers in Gauge R&R and process capability study to eliminate process variations

• Maintained records to comply with customer specific requirements - BIQS (GM), Q1 (Ford) and VDA (Volkswagen) Student Assistant CSU East Bay, Reprographics Dept. Hayward, CA 01/2016 – 01/2017

• Designed, utilized Photoshop and printed university-wide copy requests. Delivered requests and fixed copy machines Process Engineer S. Karthick Auto Air Conditioner Pvt. Ltd. Chennai, India 06/2013 – 07/2014

• Was responsible for the planning, purchasing, scheduling; supervised and organized over 30 employees

• Assisted continuous improvement and cost reduction activities focused on design and manufacturing process

• Prioritized, prepared and controlled production schedules, planning documents, Bill of Material (BOM) and Engineering change orders (ECO)

• Coordinated procurement activities with suppliers, contractors and customers to ensure on time project execution

• Prepared engineering calculations drawings flow diagrams sequence of operations and designs using HVAC process

• Created improved procedures conducting root cause analysis and corrective action implementation for production processes

• Utilized CAD designs and created assembly drawings for machining, welding and gagging

• Assisted project leaders with customer quality target requirement negotiation

• Implemented and monitored advanced quality planning with suppliers and reviewed their manufacturing processes and quality systems. Conducted audit and internal quality control programs Manufacturing & Quality Control Intern Ford Motor Company Chennai, India 01/2013 – 06/2013

• Acquired in depth knowledge in plant assembly line operations, manufacturing processes, vehicle launch and quality control

• Created and maintained databases for tracking validation activities and test results; validated systems in line with Ford’s commitment for stringent testing that ensures every car is at its best, even in trying conditions

• Examined Six Sigma process, Quality Management Systems, Value Stream Mapping, Mistake Proofing, 5s - Kaizen and DMAIC process detailing an overall strategy for consistency in the market; prepared a thorough report

• Prepared PPAP/APQP documents and operator work instructions (SOP) for the production process in machining of the parts

• Ensured that Customer, internal and supplier quality corrective actions (8D’s) meet timing, quality and format requirements.

• Participated in creating and updating Design Failure Mode Effects Analysis (DFMEA), Process Failure Mode Effects Analysis

(PFMEA) and Implemented FMEA troubleshooting technique to study the failure of engine sensors

• Assisted the Plant Vehicle Team (PVT), quality managers, and others with fieldwork, as well as improvement and cost reduction activities related to design and manufacturing processes

• Reviewing design and final drawings for approval of the new product launch (NPI), with suppliers and senior design engineers

• Identified areas of obstruction/quality failures (root cause), advising on system and process changes for qualitative improvement In-Plant Training Integral Coach Factory Chennai, India 06/2011 – 07/2011

• Observed processes, quality, assembly and production of mass transit train-manufacturing plant

• Studied design and manufacturing of engines, coaches and its various processes in the building of rail coaches from scratch to the final product, as well as plant maintenance procedures

• Understood various weld form symbols on blue prints and size of fillet forms

• Coordinated with suppliers and ensured timely supply and quality of raw materials

• Developed and implemented parameters for quality testing

• Solved problems in the shop floor by working closely with production people involved in fabrication, machining, assembly and testing areas


• Awarded First Place - Paper Presentation, “Automatic Side Stand Retrieve System” at Panimalar College, Chennai, India

• Ranked first in the Robot Rumble Competition at Saveetha Engineering College, Chennai, India

• Active Member of The American Society for Quality (ASQ) RELEVANT COURSEWORK

Total Quality Management / Applied Quality Assurance / Maintenance Engineering / Engineering Economics & Analysis / Project Management / Automobile Engineering / Global Supply Chain Mgmt. / Kinematics of Machinery / Manufacturing Technology / Systems Simulation / Enterprise Planning & Control / Product Process Design / Systems Modeling / Basic Electrical & Electronics SELECTED COURSE PROJECTS

Product Process Design - Automatic Hydraulic Scissor Jack 2016

• Designed innovative automatic hydraulic scissor jack to replace the automotive tire by lifting the chassis of a car using the hydraulic energy with the use of the cylinder instead of threaded shaft to lift the jack, which reduced the human effort and time to lift the car.

Analysis of Tesla Model S 2015

• Studied and analyzed a systems modeling report on Tesla Model S using design evaluation and decision making, systematic elimination method, graphical and tabular additive method, economic evaluation, operation and maintenance cost, social impact analysis.

Analysis of Cold Testing in Diesel Series Engine 2013

• Researched and analyzed “Cold Testing in Diesel Series Engines” in Ford India Pvt. Ltd located in Chennai, India.

• Worked on engine Cold Test machines to verify that the engine assembly process is in control and monitored the methods for quality tests of diesel engines at the end of the assembly line. Cold testing of diesel engine system found issues introduced during the final engine assembly stage; included high-speed, low speed and static tests with operator inspection. Detected low vacuum, bad oil pump, EGR valve functionality, incorrect engine timing, leaking fuel rail, damaged fuel injectors, knock sensors and missing/damaged gaskets. Created a cold test engine library for diesel series engine, which contained all details about sensors in an automobile engine and their root cause for failure. Automatic Side Stand Retrieve System 2011

• Designed and fabricated “Accident Preventing Automatic Side Stand Retrieve System” as most motor vehicle accidents in India happen due to ignorance of the side stand; thus, a mechanical device for auto retrieval of the side stand as soon as the bike starts to move needed to be fabricated and applied on different bikes, and studied.

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