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Engineer Quality

Detroit, Michigan, United States
March 18, 2019

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Mahesh Babu Burullu


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•Dynamic and upcoming engineer with a master’s degree in mechanical engineering from University of Michigan, 2 years of experience in Mechanical, Quality engineer and Systems. Now actively looking for a career opportunity as a Mechanical/Manufacturing/Industrial engineer with an immediate availability.

•To perform Stack up studies to validate tolerances and root cause design issues. GD&T ASME Y 14.5-2009.Support teams in root causing the dimensional issues.

•Utilize Lean manufacturing techniques to increase operational efficiencies of manufacturing cells and surrounding processes

• Strong knowledge in all phases of Product Development Life Cycle process, Design, validation, Production part approval process (PPAP), DFMEA,PFMEA and automotive testing, US-CAR,ASME dimensional standards.

•Estimate costs for quotes of material and labor for both company standard and customer designed products.

•Experience with seat system design and manufacturing processes, sheet metal stamping, and injection molding. To support with DV/PV builds and verify that parts meet dimensional and functional requirements.

•Create and maintain the BOM and communicating with manufacturing plant about the changes.

•Working with the plan about the measuring and the fixtures strategy.

•Spearheaded production analysis, product validation testing and upgrades to existing product designs to improve functionality, resulting in cost reduction and decreased production time.

•Developed and oversaw records system for historical tracking of all documents and drawings, increasing company efficiency and organization.

•Drive dimensional improvement through innovation and lessons learned from previous projects. To perform dimensional tolerance stack studies.

•Strong communication skills with ability to work with cross-functionally with hardware, systems and manufacturing teams. Strong analytical and problem solving skills.

•Familiarity with gauging and measurement tools for root cause analysis. Familiarity with Cp/Cpk, Pp/Ppk.

•Strong knowledge on mechanical engineering, particularly very sound in design, engineering analysis.

•Working knowledge of Operating Systems like Mac OS Yosemite, Mac OS-X, Windows 2003, Windows XP, Vista, Windows 7 and Windows 8, Unix and Linux.

•Excellent communication, organizational skills, attention to detail and the ability to meet tight deadlines. Capable of multi-tasking at work and taking up challenges and energetic and passionate for learning new concepts, methods, and technologies.

•Willing to relocate Anywhere within the USA

•Authorized to work in the US for any employer.


•Master of Science in Mechanical Engineering from University of Michigan Dearborn, USA in April 2017.

•Bachelors’ degree in mechanical engineering from JN Technological University, Hyderabad, India in June2015.

Areas of Expertise/skills:

Design Software: Auto Desk inventor 2016, 2017, Catia V5 R21, Uni graphics NX 9.0, 10.0, Team center 10.1 GM module.

CMM programming: Metrology X4 and PC-DMIS.

PPAP, AAR, APQP, DFMEA, PFMEA, Gauge R&R, CP/ CPk, First Inspection methodology.

Engineering: GD and T ASME Y 14.5 2009. Strong ability to understand creates, apply, and interpret GD&T per ASME Y14.5-2009 standard. Develop datum strategies, dimensional specifications, and measurement plans.

Other skills: Ms Office, Mini Tab, SAP-MM, SAP PDM, Creation of BOM,

Work Experience:

CMS Software

Client: General Motors

Designation: Dimensional systems Engineer (Body/Exterior) October 2018– January 2019

Responsible for Geometric Dimensioning and Tolerance (GD&T) Template Development.

GD&T responsibility for vehicle components and assemblies based of best practices, previous program leanings, 1D stack studies,3D Variation analysis.

Proficient with NX, Team Center and Team Center Visualize Able to cut sections and analyze CAD data.

In charge of exterior fits (gap and flush) of all closure assemblies in body shop and final.

Solved daily build issues as they are identified in the plant, BIW, Closure hang, Door Claddings, Flares, sills and in trim chassis final.

Responsible for Dimensional Engineering Exteriors, Closures and interiors components and sub systems such as Door in White, Hood, Lift Gate, Bumper Fascia, Exterior Trim, Headliners, Head lights, tail lamps, Sunroof Systems.

Assigned to E2YB, E2UB, D2UG MI 22, E2UL MI 22, C1XX MI 23, T1SUV MI 22, programs as a dimensional engineer.

Responsible for design, development and release activities of bumper fascia grille system for a high volume SUV manufactured across multiple plants.

Lead product development team and coordinated with program team for project progress and issues.

Worked on programs with very high engineering variants and multiple suppliers and plants.

Strong knowledge of manufacturing processes for plastic, composites and sheet metal parts.

Used methodical approaches such as DFMEA, DFM/DFA, DFSS, APQP for a robust design implementation.

Issue resolution using problem solving skills like 8D, Problem tree analysis, Red X.

Well versed with OEM Product development phases and product management systems like E2, Edge, and APM.

Body closures is responsible for leading the design and development activities for Body closures components on new or current vehicle programs to ensure with Technical requirements.

Responsible for Interior and Exterior dimensional validation, Creation Kaizens and eCims from QAF build issues and part validation, Root cause analysis, ensuring part availability for the QAF builds, Launch support and supplier interface

To locate and datum scheme development, documentation and coordination between parts & tooling. Dimensional analysis (1D and 3D) to mature concepts and drive dimensionally optimized designs.

Analyze statistical data in order to establish target based design compatibility and to make recommendations. Support the development of part and system based tolerance requirements through GD&T with Design, Manufacturing and Quality.

Review assembly and measurement tooling in order to ensure alignment with agreed and optimized design strategies. Provide initial product assembly process support (Prototype, Pre-Release and ramp).

Support plants in root causing dimensional issues. Work with cross-functional team to recommend and evaluate corrective action.

Drive dimensional improvement through innovation and lessons learned from previous projects. To perform dimensional tolerance stack studies.

Precision jig and fixture.Inc

Designation: Quality Engineer October 2017– October 2018

Dimensional inspection and a broad range of gage and fixture certification.

Program/operate CMM with metrology x4 and CMM Inspections. Including Fixture certifications, part layout, Cap studies, Gauge R&R.

Advanced knowledge of GD&T principles and their relation to inspection. The ability to use this knowledge to facilitate communication between Design, Production and Metrology to better serve the customer.

Worked For BMW, VOLVO, FORD Companies plastic parts Quality Measurements plastic, sheet metal Parts according to GD&T, Blue print and Customer requirements and making the reports.

Create and execute Gage R&R studies and assist in the facilitation of product capability studies on new and current programs.

Perform Capability Studies and measurements for calibration, Compensation, and Certification activities, related to ISO17025 laboratory requirements, and measurement of artifacts.

Create a Programming of CMM using software Metrolog X4.

Good knowledge on A2LA and ISO 17025 Accredited laboratory.

Creation of layouts for quality control bench line using Auto CAD, and also converting 2D Engineering Drawings into 3D models as per customer’s request.

Participate in check fixture designs; obtain customer approval for fixture designs; Coordinate efforts of fixture sources and Center layout to obtain certifications (Dimensional and Gage Repeatability and Reproducibility).

Cross functionality with manufacturing, design and tooling teams.

Creation of 2d with all GD & T, and maintaining dimensional reports, to perfume gage design and check fixture follow-up activities.

Review and analyze of check fixture designs, and manage the continual improvement of the process.

Good knowledge in Datum’s, Locaters, nets, SPC(statistical processing control) etc..

Surabhi Spinning Pvt. Ltd (Cotton Thread Fabricator), Hyderabad, India

Designation: Quality /Mechanical Trainee Engineer March 11th 2014– April 28th2015

Inspected CNC machines (Part Program) and Working conditions of the machine.

Reviewed the materials to ensure readiness to dispatch for customers.

Work with customers to review testing requirements and ensure that system is being met and oversee PPAP process.

Develops manufacturing processes by studying product requirements; researching,designing, modifying, and testing manufacturing methods and equipment; conferring with equipment vendors with team.

Improving manufacturing efficiency by analyzing and planning workflow, space and equipment layout.

Taking manufacturing decision by information provided and calculating, labor and material costs.

Prepares Production reports by calculating, Analyzing and summarizing information and trends.

Providing required information to the team from manufacturing point of view.

Monitoring equipment maintenance system and make request to maintenance department if needed.

Supervising operators and allotting work to employers according to the manufacturing requirement.

Communicating to quality department if any issues or quality concern in the manufacturing line.

Research Projects:

Project- Modal Analysis of a Leaf spring University of Michigan 2015

•Introduction: The modeling and analysis of a Leaf spring as per the design requirements for safety and durability by performing Modal Analysis using ANSYS Workbench.

•Analyze the different mode shapes obtained and determining the natural frequencies.

•Get a clear idea about performing Modal Analysis in ANSYS Workbench and its significance in vehicle structures.

•Geometry from CAD used for analysis must be able to get meshed into precise and reasonably small finite elements

•After the leaf spring was meshed, the Analysis Settings were changed in the ANSYS Mechanical Interface as needed.

Bio- Diesel Powered Vehicle Nov 2014– May 2015

•Introduction: Diesel engines are widely used as power sources in low medium and heavy duty applications because of their low fuel consumption and lower emissions of gasoline engines.

•Lower heating value of the biodiesel caused an increase in specific fuel consumption of the bio diesel.

• Brake thermal efficiency of the biodiesel improved due to engine power torque did not deteriorate too much according to diesel fuel.

•Designed and Analysis: Designed (Auto CAD) a portable Eco-Friendly vehicle and Analyzed (ANSYS) its potential.

•Manufacturing: Manufactured the vehicle as designed for further process.

•Modeling the car frame using ANSYS software.

•Alternative: Used (Pongamina seeds) instead of Diesel for Eco-Friendly.

•Performance: checked the vehicle on road and found its performance as 25kmp/liter.

Generating CNC part Programming on PRU Base Plate:

•Introduction: PYRO RELAY UNIT (PRU) is a part of an electronic package being used in AKASH missile. For any missile, identification of target is very important.

•The component is designed using NX_CAD software.

•3D model of PRU BASE PLATE is created using UGNX-7.5 –CAD.

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