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Six Sigma Mechanical Engineer

Detroit, Michigan, United States
February 28, 2018

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DEEPIKA NEGI 6558 Winthrop Street, Detroit, MI-48228 Master of Science- Mechanical Engineering-University of Texas At Arlington Jan 2016 –Dec 2017 Bachelor of Technology- Mechanical Engineering-University of Mumbai, India Aug 2009 –July 2013 GPA:3. 5

GPA:3. 6


• A passionate and highly dedicated Mechanical Engineer (Master’s) with a 2 years hands-on experience in Automobile Industry.

• Documentation: EQ (IQ, QQ, PQ), ECR/ECO, Software Validation, Process Validation, PPC, BOM and MSQ. Generating OMS, QPA, PDL and Work Instructions.

• Methodology: Six Sigma and Lean Manufacturing. Certified Six Sigma green belt (CLSSGB)

• Quality tools: 5why, Fishbone Diagram, Product Life Cycle, A3, 8D, Just in Time, SMED, DFA, DFMA, DFMEA, PMFEA, DVP&R and DFSS.

• Experience in GD&T, Bill of Material, Tool Design, fabrication, Manufacturing and Assembly Method Knowledge (Injection Molding, Blow Molding, Sheet Metal Design, Snap Fit Design, Jigs & Fixture, TIG, MIG, Robotic and Vibration welding), Statistical Analysis.

• Solid works 2016, CATIA V5, EM Works, AutoCAD 2016, FEMM, Inventor, NXCAD, Minitab, MATLAB and Simulink.

• CAD modeling, Drafting, Dyna-Cam, FEA Analysis, Microsoft office, SAP. SKILLS:

Value Stream Mapping, Industrial Engineering, Product Development, Continuous Improvement, SPC charts, Quality management Process Diagrams, TQM, Six Sigma Quality, Factorial Design, GR&R, CNC Machining, Process Capability Study, Project Management, Process Improvements, Manufacturing operations, Process Mapping, drafting, Automation, Manufacturing Engineering, process design. EXPERIENCE:

Manufacturing Engineer MK Precision Metal Parts Private Ltd India Jan 2015 – Sept 2015

• Designing Fixtures (welding, inspection, machining), plastic injection molds for automotive products by applying GD&T.

• Responsible for checking molding feasibility of parts at quoting level utilizing Moldflow analysis/ Thickness Analysis/ Draft Analysis in SOLIDWORKS Plastic.

• Create Design Validation and verification Plan & Report (DVP&R) report showing areas which are not feasible to mold or require design change

• Creating guidelines for Molding Tool Construction with recommending basic need such as a number of cavities, gates, sliders, lifter, type of ejection, steel and cooling required.

• Reviews Current running tool condition reports and reply with recommendations on production jobs released to the Tool Shop.

• Drive quality improvements using solid engineering tools such as Statistical Process Control (SPC), Lean, Six Sigma, DMAIC (Define, Measure, Analyze, Improve, Control) problem-solving.

• Coordinates the manufacturing launch of new product development (APQP, DFM), including product analysis & cost structure.

• Work directly with Process Engineering to perform all engineering process samples and documents on “tryout” checklist.

• Provide Technical expertise in manufacturing processes including flow, layout, assembly, tooling, etc.

• Analyze dimensional layouts and metrology and make decisions on corrective actions.

• 3D modeling of plastic injection molds, MOLDFLOW analysis for defect analysis, gate location, conducted DOE studies to optimize the process.

• Improved downtime in mold processes through root cause analysis and updating mold release equipment.

• Performed Time Study and process analysis to identify process wastes and implemented solutions to reduce cycle time by 20%.

• Documentation of Production Part Approval Process (PPAP); ballooning of drawing; creating process flow charts.

• Conducted internal auditing of production and warehouse operations, investigated the root causes of CAPAs and suggested corrective action for persistent product failures. Created Material Masters for all parts and added them to the Bill of Materials in MRP system.

• Reading and understanding blueprints, bill of materials and technical references to create processes on different machines. Manufacturing Engineer Star Auto Private Limited India Sept 2013 – Dec 2014

• Applied Lean Manufacturing techniques-PMFEA, Kanban, Kaizen and 5 Why processes to ensure the cost-effective manufacturing process.

• Applied Six Sigma techniques for Cost Reduction, Minimize the Error and Improve the Quality of Car Interiors.

• Prototyping by using 3D printing (MakerBot Replicator 2x) or by building prototype molding tool from the concept design. Worked on Process Development, Designing and Automation of Robotic Arm used for Painting the Plastic Product of Car interiors.

• Manufacturing and Development Knowledge of the Plastic Pats and Products including Feasibility studies, Class A surfaces, Class B Attachments and Drawing for automotive parts. Provided Technical design support to Sales and Quality Engineering Departments.

• Worked on Troubleshooting, PV, EQ and Automation of Plastic Injection Molding Equipment.

• Applied FMEA, DFMA, 5S and Poka-Yoke methodology to ensure better quality and the effective cost of the product.

• Designed sub-assembly cells for one-piece flow to manage manufacturing capabilities with high focus on safety and ergonomics.

• Handled Inventory and Shop Floor Management. Using TEAMCENTER (PLM) to manage design, update revisions and approvals.

• Worked on sheet metal processes like stamping, Punching, Bending, Drawing and Shearing.

• Created VBA scripts in MS Excel to solve Manufacturing issues relating to downtime, traceability, and yield.

• Working individually and in teams in order to achieve company’s goals and dealing with problems. PROJECTS:

• Application of Kinetic Plates in Energy Generation (CATIA V5, Ansys) Development of Kinetic Plates used for power generation using the weight of automobiles. Design and analysis of each component of the system (Rack, Pinion, Spring, Chain-sprocket &gear mechanism, Flywheel, Generator)

• Evidence of APQP in Quality Improvement

Application of APQP methodology for quality improvement in (SMEs), using a specific die casting case.

• CAE Applications in Automotive Trims (ABAQUS)

Various techniques and methodology used to predict the snaps insertion and the retention force for different types of snap-fits.

• Using FMEA in a Precision Sheet Metal Parts Manufacturing Company Eliminate current and potential problems from a bending process using Ishikawa diagram and Failure mode effect analysis. RELEVANT PROJECTS

QUALITY (Continuous Improvement &Six Sigma Tools): 1. Six Sigma Green Belt Project - CVS Pharmacy

• Inconsistencies in the Inventory storage unit have been solved using the DMAIC process.

• Process maps have been developed to measure the current state of the process.

• Root cause Analysis has been done using why- why technique and 5S technique has been adopted to solve the problems.

2. Kaizen implementation in readymade garment industries

• Applied Six sigma tools to locate waste and improved transactional processes using process improvement tools such as Kaizen, WIP (Work in Progress), fishbone Diagram, Value Stream Mapping(VSM) implemented 5s in this area. 3. Process Improvement using DMAIC approach

• Executed DMAIC methodology to minimize the product changeover time and reduce the cycle time deviation without affecting the quality of the product

• Identified problem using data analysis and pareto charts. Narrowed down the scope to focus on major issues.

• Applied various lean tools to figure root causes, methods to eradicate causes and stabilize process.

• Reduced downtime and improved production processes, increased production 11.45% overall.

• Tools used: SIPOC, VSM (Value Stream Map), Pareto charts, Ishikawa, Cause validation tables, Prioritization matrix, NGT, JMP, MS Visio.

4. Enterprise Resource Planning using SAP

• Hands on experience on real life business situations related to procurement, fulfillment, accounting & inventory using SAP.

• Strategic issues that resulted in major failure of ERP implementation.

• Being a part of this project team helped me in gaining real world experience of SAP and its implementation failures. 5. APQP methodology for quality improvement in small and medium sized enterprises- Die Casting Case

• Studied APQP and tools to diminish the rejection rate in die casting of a SME.

• Identified problem using data analysis, pareto charts, process flow chart, Fish bone Diagram, PMFEA, FMEA, Control Plan.

• 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. 6. Shop Floor layout improvement through Floor-Cleaning Machine

• Designed a primitive model of a floor cleaning machine which is based on Hoeken’s Linking mechanism using 3D modelling software and manufactured it using conventional manufacturing techniques

• Overall cost to market of the machine was nominal owing to the simplicity in design and implementing it in the shop floor yielded 25% reduction in the overhead cost of that industry 7. Using Failure Mode Effect Analysis in a Precision Sheet Metal Parts Manufacturing Company

• Analyzed the potential causes of failure from a bending process using cause and effect diagram and why-why analysis.

• Developed a detail process FMEA of cause of failure of the components and analyzed the effects by using risk priority number(RPN).

• Recommended possible corrections in the process to reduce the causes of failure of the components.

• By implementing the recommended process change, quality check process & continuous PDSA cycle, causes of failure can be controlled, which results in a change of 30% in next 3 months. DESIGN AND MANUFACTURING PROJECTS

1. Development of Kinetic Plates (which were installed on roads) used for power generation using the weight of automobiles.

• Final year Bachelor Project - Conception and development of kinetic plates (which were to be installed on roads) used for power generation using the weight of automobiles. Designing and analysis of each component of the system (Rack and Pinion, Spring, Chain sprocket and gear mechanism, Flywheel, Generator)

• Software’s – SolidWorks, Catia V5.

2. Design of Motorized Wheelchair for elderly people at domestic places–Catia V5

• Stair climbing functionality was the focus in its structure and mechanism. The product covered 3 modules viz. seat, links and frame.

• Digital Mockups of individual parts were developed in CATIA and assembled to form the final product.

• Wheelchair is embedded with some additional features like integrated commode facility, after gathering costumer requirements from different subjects.

3. Design and fabrication of drilling machine

• Developed a portable drilling machine which mainly focused on the hurdles faced in drilling of thin metal sheets, thin foils and paper.

• The project is aimed at designing and fabricating a self-clamping drilling machine which would help in fully reducing, if not eliminating, such undesirable outcomes in the drilling process.

• Design and analysis were conducted using Solid edge, Auto CAD, CATIA respectively to check if the design could perform the operations without breakdown. The main considerations for the drill setup are stability, safety and accuracy. The next major focus is on the self-clamping mechanism, main concern being mechanism for automatic return of the clamp after drilling as well as clamping the work piece just before the drill bit approaches for drilling.

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