Manufacturing Engineer

ABHIJITH RAO R

*** ****** ***, ********* *, Warsaw IN 46580 Email: ********.*****@*****.*** T:914-***-****

https://www.linkedin.com/in/abhijithraor

SUMMARY

Mechanical Engineering Graduate with proven leadership abilities and experience with academic training.

Mastery in 2D and 3D modelling with hands on Manufacturing and Quality Innovation.

Driven knowledge on applications like FMEA, PFMEA, COPQ, CAPA, PPAP, and APQP.

Competency in medical device risk management (ISO 14971).

Hands on experience in using Lean manufacturing principles and experience with ISO 13485.

Good knowledge using Failure Mode Analysis tools on Design for Reliability (DFR), Design for Manufacturing (DFM), design for Testing (DFT).

Industrial Experience with activities like Design Review, Blueprint Reading, APQP, PFMEA, Control Plan, PPAP, SPC, MSA, IMDS, 8D, Time studies.

Skilled in developing control charts, X-BAR and R- BAR charts, Fish Bone Diagram.

Worked extensively on reliability projects and project management case studies.

Excellent research, time management and problem solving skills.

Highly organized with the ability to manage multiple projects and consistently meet deadlines.

Understanding and implementing engineering change orders and requirements according to customer needs and specifications.

EDUCATION

Masters in Mechanical Engineering Jan 2015 – Dec 2016

University of Bridgeport 3.36/4.00

Bachelors in Mechanical Engineering June 2010 - June 2014

Visvesvaraya Technological University 3.22/4.00

TECHNICAL SKILLS AND EXPERTISE

AUTOCAD, CATIA, SOLIDWORKS, TEAMCENTER

GD&T, Bill of Material (BOM)

Kaizen, Error proofing, Standard work, VSM

Team center, Root cause analysis, Balanced flow

SAP, Infinity Quality System, ENOVIA

MS office suite ( Excel, Word, PowerPoint)

Process layout, flow diagram, Assembly process planning

PROFESSIONAL EXPERIENCE

Manufacturing Engineer- ZIMMER BIOMET August 2017- June 2018

Worked as per 21 CFR 11, 21 CFR Part 820, ISO 13485 standards and FDA regulations.

Responsible for providing manufacturing engineering services to support cellular manufacturing and timely new product introductions. Engineering services include process development, cell management, tool design, and CNC programming.

Evaluated non-conforming for deviations from products like as regenerex glenoids, gleno-spheres, Base plates, hip stems, tib trays and execute tests to verify Nonconformance reports (NCR) and Common cause rework (CCR).

Performed Equipment Installation, Manufacturing Process Characterization, Operational Qualification, and Performance Qualification (IQ/OQ/PQ) activities, as well as Software Validation and Test Method Validation for manufacturing equipment and processes.

Worked with vendors in procuring materials, equipment.

Reviewed product related issues with execution of Corrective and Preventative Actions and verification of effectiveness with appropriate problem solving techniques. (DMAIC, FMEA, Ishikawa, Fault Tree).

Worked with Manufacturing and QA to identify root cause of quality defects and implement permanent corrective actions.

Trained production personnel on software such as Infinity QS and Delmia on the production floor.

Ensured that process, products and materials are in conformance with the internal quality standards and customer requirements.

Designed, developed, and verified product design changes using computer aided design (CAD) software following design control procedures.

Analyzed product data to ensure released product meets customer specifications, and generate reports for product certification.

Conducted data analysis with the goal of verifying part quality, processes, and data.

Junior manufacturing Engineer- MSPL Gases April 2012 – December 2014

Identified and addressed product quality issues and continually looked for ways to improve processes at the plant. Also, supported 5S and Lean Projects while continuously identifying ways to reduce plant operating costs through the incorporation of Operational Excellence strategies.

Managed engineering changes, Continuous Improvement, 5S, working with cross-functional team to ensure timely execution.

Reported progress and concerns related to inspection activities, nonconforming items related to the quality of the process, material, or product.

Established process methods which meet performance and quality requirements.

Designed, developed and analyzed using creo for customized elbows for pipe lines.

Used BIM as 3D plant design software to efficiently utilize plant layout.

Manufacturing Engineering Intern – JSW Steel Works ltd. January 2012 – March 2012

Lead problem solving investigations and quality improvement (Kaizen) activities and 5S to embrace the continuous improvement of logistics quality.

Gained real time industrial experience during the training in the various zones involved in the steel making process namely Raw Materials Handling Plant, Coal Ovens, Steel Melt Shop, Blast Furnace and the Milling Zones.

Coordinated with the Central Maintenance Mechanical Department in the maintenance of the manufacturing units.

Identified areas of obstruction/breakdowns and taking steps to rectify the equipment's through application of trouble shooting tools.

Measured operational pressure and temperature of the blast furnace which in turn is responsible for the flow of hot metal into the ladles with flow rate of 6 tons per minute.

ACADEMIC EXPERIENCE

Improvement of dip tube retention using six sigma principles for APTAR group:

Achieved process capability (Cpk) of 2.99 for dip tube retention by applying DMAIC approach and reducing the customer complaints by 80% in 2016 by finding the cause using root cause analysis technique.

Design and development of a flywheel:

Created a design of a fully constraint model by using CATIA and Creo software and analyzed material properties using ANSYS workbench. Selected best material considering manufacturability, cost, weight, performance, assembly and service.

Design and development of liquid bottling production line:

Designed chuck assembly using SOLIDWORKS for automated capping machine and performed chuck assembly analysis for different torque values using the same. Also, reduced changeover times between batches of production.

Design, fabrication and development of raspberry pi-2 casing:

Designed a raspberry pi-2 casing on Solidworks and increased the overall efficiency.

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