Manufacturing Engineer

Manjunath Sundarapandian

**** ***** ******, *********, ** 14620

Email: *********.*******@*****.*** Phone: 607-***-**** MANUFACTURING/QUALITY ENGINEER

Industrial & Systems Engineering graduate with 3+ years of experience working as a Manufacturing/Quality Engineer for a major Automotive and Building Products Manufacturer. Possess the analytical abilities and technical skills necessary for engineering innovative designs and applications. Solid understanding of Lean and Six Sigma Tools and methodology, DMAIC, PPAP, 8D Analysis, Kaizen, Kanban, Process development and improvement, Supplier management, GD&T and APQP, Statistical Knowledge (SPC, DOE, CPk). Working Knowledge of Quality Management Systems (ISO 9001). Lean Six Sigma Green Belt Certified

EXPERIENCE

Studco Building Systems US LLC Webster, New York

Building Materials - Global building systems manufacturer Manufacturing & Systems Design Engineer Mar 2017 – Present Managing and designing new manufacturing plant related projects that increases production line efficiency, reduces costs, and optimizes operational processes and Formulating documents and procedures to ensure compliance with the Quality Standards. Key Contributions:

Performed problem solving in milling operation and assembly line using 8D and 5 Why methods to address customer complaints and internal quality issues

Prepared Core Tools (PFD, PFMEA, and Control Plan) package for sheet metal cutting parts.

Conducted Process and Product audits to reduce non-compliance to achieve customer satisfaction

Developed VSMs for 10 value streams within the assembly process with 8 to 10 kaizen’s identified for each, prioritized kaizen’s and root causing and implementing SOP’s for continuous process improvement

Developed Bill of Materials (BOM) and routing sequence in the ERP systems for new product Introduction (NPI) and improved the traceability of every product being manufactured that increased quality and reduced cost of products.

Successfully Implemented a Statistical Process Control (SPC) for milling operation to study the capability of the process (Data Analysis) based on a weekly basis (Reduced waste involved in the process/50k savings a year)

Investigated and troubleshooted faulty operation of equipment during the Non-Conformance events to confidently recommend solutions to maintenance crew by performing the root cause analysis (8D, 5 Why techniques)

Wrote and implemented new standard operating procedures (SOP) for New Product Introduction (NPI) and trained Technicians and Operators for new processes, quality requirements(ISO 9001) and safety (OSHA) Toyota Material Handling NA/Raymond Corporation Greene, New York Automotive - Forklift Truck Manufacturer

Manufacturing/Quality Engineer Aug 2016 – Jan 2017 Supported Manufacturing production and evaluated different applications including laser sheet metal cutting, CNC Machining, bending operations, assembly processes for continuous process improvement. Key Contributions:

Performed root-cause analysis and other problem solving activities through 8D, 5 Why techniques to identify effective corrective actions and implement process improvements

Performed process capability and MSA (GR&R) studies for drilling operation to identify factors that affect variability

Performed Gemba walk in the facility to monitor and improve quality and production

Implemented a Statistical Process Control Study (Control Charts) in a bending operation to eliminate the magnitude of rejection involved in the operation (Cut down cost by eliminating the waste)

Successfully modeled and setup a discrete event simulation study using Arena based on the results from process time study to identify bottlenecks and value stream the process layout and achieved 10% increase in takt time efficiency (Short term Implementation) on a multi-line product assembly line. Proposed an Automated Guided Vehicle in the process layout based on the study to achieve the 25.5% increase in efficiency (Long term Implementation).

Re-designed an Andon system for an Automated laser sheet metal cutting machine that needed manual operation to calibrate the tooling for change in gauge thickness (reduced process delays and improved process time)

Successfully closed multiple Kaizen events on a regular basis and managing and solving it to achieve continuous process improvement

Hyundai Motors India Limited Chennai, India

Automotive – Global Vehicle Manufacturer

Manufacturing /Quality Engineer Dec 2013 – July 2015 Supported transmission (powertrain) assembly lines and optimized jig/fixtures design, evaluated and re-designed poka-yoke (Quality Error proofing) systems and identified and mitigated the risk associated with workplace hazards with new human factors/ergonomics design. Key Contributions:

Developed initial control plans (SPC) and containment plans (PFMEA & DFMEA) for assembly processes and documented in accordance with Quality Standards (Quality Assurance System)

Developed and Designed (Using Solidworks) Jig/Fixture Holding device for transmission assembly lines that reduced setup times

(SMED) and increased process efficiency by 30%

Assisted suppliers in developing statistical process control (SPC) methods for inspection, testing and evaluation.

Reviewed Supplier PPAP documents for compliance with customer specific requirement.

Investigated and supported training needs for the facility (i.e. Lean Manufacturing, Problem solving, Kaizen, 5S).

Analyzed and documented the reason for rejection of transmission boxes using Cause and Effect diagram/Fish- Bone diagram and saved overall cost by 60% involved in the rework process

Worked closely with the technicians from transmission assembly department (Powertrain) to troubleshoot and increase the efficiency in an Injection molding process by successfully implementing a Design of Experiments Study to improve the process parameters.

Supported and adhered to policies, procedures, and operational guidelines related to established quality management system SKILLS

Process Improvement: SPC, VSM, DMAIC, KAIZEN, 5S, SMED, Design of Experiments (DOE), ANOVA, GEMBA

Statistical Packages: Minitab

Database Management: SQL

Packages (Design & Programming): Advanced Excel, VBA, R Language, Visio, Tableau (KPI), AutoCAD, CREO, Solid Works, Arena (Simulation)

EDUCATION

MS, Industrial and Systems Engineering GPA 3.33/4.0 SUNY Binghamton University, New York Jan 2017

Coursework: Quality Assurance for engineers, Probability and Statistics, Operations Management, Advanced Topics in Integrated Manufacturing, Modeling and Simulation, Supply Chain Management, Systems Engineering

BS, Mechanical Engineering GPA 3.8/4.0

Anna University, India May 2014

Coursework: Manufacturing Technology, Process Planning and Cost Estimation, Design of Experiments, Computer Integrated Manufacturing, Design of Machine Elements, Calculus, Engineering Management

CERTIFICATIONS

MOST Certification - Time study/ Work measurement analysis (Raymond Corp.) Aug 2016 Lean Six Sigma – Green Belt (State University of New York) Jan 2016 Master Diploma in Product Design and Analysis (3D & 2D Design, DFMA) Jul 2014 MEMBERSHIP

American Production and Inventory Control Society (APICS) – Member Jan 2016 – Present

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